Drilling out the stock 45 pilot jets to 48
 

Has anyone done this, and if so, what size drill? I want to get my bike running by the weekend so ordering new is not an option.

You can typically find mini-metric drill bits. The kehin style jets are all in metric so they can be found, but having something off regular ranges (ie factors of 5) you might have some problems. I use them in restoring old carbs and fixing the jets you just run the risk of changing the nozzle profile.

Outside of that, it looks like either oem dealer or overnight shipping are the only options for you as finding the mini-drill bits can be a pain in the arse too.

I'll take a look when I'm at the shop today and if I can hunt down a 0.48mm (which is what you'd be looking for) and I'll bring it home and PM you about shipping it. I'm fairly certain that I only have a .5 however. I don't know how that would effect things as jumping up .03mm from stock makes such a large difference.

If anyone has anything to add to going up an addtl .02mm then right now would be a time to shout it out!

I work in a machine shop so i probably have the bit in my mini index, as well as mini inspection pins. I guess i might as well give drilling it a try.

I am quite jealous!

I'm stuck using guitar strings for the off sizes =p

It works but you look like a goober standing in a music shop with a caliper measuring the width of the strings hahahahahaha. Well, atleast for cleaning the jets, not so much for drilling.