Front Fork Damper Bolt Is Wiped!

[Ed200x]

The fork seals on my 200X are blown. So I ordered new ones and proceeded to tear down the forks. Someone got there first and one of the allen-head damper bolts is rounded out. No way a allen wrench is gonna work in there! Anyone got a trick idea out there short of taking it in to the shop??$$$$$$$ I wanna go ridin!
Thanks!

[Dirtcrasher]

It is deep within a counterbored fork leg so slicing a slot in it may not work. I'd get a good drill bit a hair larger than 8mm or somewhere around 5/16 to 21/64, hopefully cobalt would work. Drill it deep enough past the bolt head and the head will break off of the threaded stud inside. That piece leftover shold spin right out with a pick or a drill in reverse. Sounds like they used the wrong hex key.....

[DeePa]

just drill the head of the allen bolt off and then you will be able to remove the fork leg. be careful though, its not easy. If you try a left handed drill bit, install all of the springs and fork caps so there is tension on the fork damper (the part inside that the allen bolt screws into). This will make the bolt not spin freely.

Impact wrenches are the easiest way to get that part off. I tried it once with regular L shaped allen wrenched and ruined 2 bolts. Ive taken about 8 of htem out now without a problem with an impact wrench