82 GPz750 (KZ750R1)fork problem

Was getting my 82 750R1's forks apart,had a problem with getting the old hex(allen) screws out of the bottom of the slider.The first one came out when I put my air impact on it.The other one stripped out the hex socket.Since I knew the top of the damper had the holder teeth cut onto it I used a 5/8th spark plug wrench put onto a bunch of extensions trick.That got the bottom screw to go around but now I got nothing stop the thing spinning.Anybody got any suggestions before I drill the head off the screw?I'm terrible at drilling straight but it's the only thing I can think of.

If you have to drill it out keeping the bit straight won't be a problem. Use a bit that is only slightly larger than the diameter of the threaded part of the bolt. The hex hole of the allen bolt will keep the bit centered. Once you drill through the hex hole into the top of the threaded portion of the bolt the allen head will come off and you can pull things apart. Depending on the diameter of the bit you may need to give the bolt a tap with a drift pin to pop the head off after drill through it. Ed

You under estimate my ability to mess up with a drill ed :blink: I know it should not be bad and it looks like what I'll have to do but I if I told you I liked it it would be a lie.

Be sure to use a high quality drill bit. The allen bolts seem to "work harden" as you drill them so it may take a bit of time to drill off the head. Ed

Hmmmmm......Might just need to get a new one then.

I would apply heat w/ a propane torch & also use a penetrant, letting it sit overnight.
Apply heat, after it cools a bit pour water on it, apply heat, pour water, then the penetrant.
Next day same thing, then try to extract the bolt.
Vibration can help as well --- fit a junk tool into the head, then tap, tap, tap w/ a hammer.
For fasteners w an exposed head, I use an oak wood block on the bolt head instead of a tool.

Well I bit the bullet and drilled the head off.Like ed said it wasn't to bad.Used a little to small a bit to begin with though as it was going past the head with no release.A bit of drilling with one size up and she popped.When it was done the stub came out with light finger pressure :blink: