Frozen bolt in Fork!

Just bought this used bike...and inherited someone's problem along with it. One of the 8mm 1.25 x40 mm allen head bolts was stripped. So I used a Craftsman easy out in a drill, but it is so tight after drilling into it and plunging the tool into the hole I can not budge it. My crescent wrenches are getting furrows dug into them from the case hardened easy out.

All I can imagine to do is heat the area around the bolt..which is aluminum alloy I presume. ANy ideas on heating aluminum? I know it is very easy to warp it. And will heating it affect my fork oil? Perhaps heating a little at a time? I can heat the other side of the stud hole but really don't want to blister the paint on the fork. If I do heat it, what paint can I use to touch it up with? Seems like it is a baked on finish... Any ideas would be appreciated.

disregard,picture wasnt working earlier. :sick:

It is a 1995 Kawasaki GPZ 1100. Fork legs...sounds expensive. I just want to change the tire.

Ok I got your picture to work now,it was all blurry before. :blink:
I was thinking of the older style fork legs.
Can you possibly gain access to an impact to try and loosen it?

I wonder if somebody didnt use red loc-tite on those bolts in the past which usually requires heat to loosen :sick:

If the threads in the fork leg were thrashed to the point somebody had to put red loc-tite on there and force it in you might be better off from a safety stand point to find another set of forks,I just pm'd Brian about your post he might be able to fix you up with a set of forks cheaper than you think.
Suspension/brakes are an area I definately dont suggest cutting corners on

To use an impact is not possible. the bolt sticking out in the pic is and ez out. No place to put an impact.

Is therev enough of the allen head left to get an allen head socket into to use an impact on?

Do you have somebody who can weld an allen head socket into whats left of the bolt so you can get an impact on there?
That might get it hot enough where you can shock it loose.

You might try some penetrating oil. Also, you can try using an impact drill with your screw remover. Be sure to wear safety goggles though.

The ez out is stuck in the allen head. AM going to heat it.

I wouldn't advise heating aluminum, for obvious reasons. If all else fails, get a drill and some patience.

Use Kroil on it for a couple days, then unscrew it. Ed