I had this problem on my KLR in South America. I needed a sprocket in Ayacucho, Peru and the closest place to get one was La Paz, Bolivia. The solution is extremely simple:
I talked to a motorcycle repair shop in Ayacucho and they said, no problem! They found a sprocket from a different bike with the same number of teeth (43 on my old model KLR), cut out the bolt holes from both my sprocket and the new sprocket, then welded the bolt holes from my sprocket to the new sprocket teeth.
The result was almost perfect (but I could feel a VERY tiny catch from not being exactly centered). I rode something like 2,000 km on that sprocket before I replaced it in La Paz (along with new chain and front sprocket). I called it my FrankenSprocket.
It took me about 2 hours and didn't even cause me a delay.
Here is my original blog post on it with pictures. Not much detail to the story, which shows how much of a non-event it ended up being.
FrankenSprocket | Othalan's Travels
Good luck!
Edit: Just noticed this is several days old and not recent (oops), hope you got it sorted out!
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