I thought of that. The wheel was respoked at some stage, but it does appear to line up OK. I did do a little adjustment and moved it right by a few mil but that hasn't helped a lot. I don't really want to pull it apart and respoke it. I reckon the spacer idea is the best bet, I'll use the centre ring of an old sprocket.
Are you sure?
If the chain line is correct and it is only a tire that is too wide causing the problem, then why complicate it by messing with the sprocket alignment? You will end up fouling the chain guide by spacing it out 5mm.
If the wheel you are using has the correct spacers [in the correct places] it shouldn't be anywhere even close to 5mm out of line. If the tire is still too close, then I think that the rim is not centred correctly and the offset is wrong. It is easy to make a mistake as the RM swingarm is assymetrical.
If somebody with an RM250 could measure the rim offset - [as it is on the bike, a straight edge on the outside of the sprocket - and then measure the distance from the straight edge to the lip of the rim]. That would give you a good idea if your wheel is laced correctly.
I would do this before messing around spacing sprockets.
But Graeme, you really should have known that you would have a problem or two after announcing that you were ready for CD9 3 weeks early. That is Mr Murphy Bitch-slapping you for your over confidence. Doh!!!