Piaggio Sfera 50, Variator Issues

So I've got a '91 Sfera 50, has a 70cc kit, bigger Delorto carb, different exhaust, and a Malossi variator.
The problem is that most of that tuning was done by a previous owner, so I don't know exactly all what was done, mainly when it comes to a variator.
So, first issue is that it appears I'm missing the spacer between the rear clutch/variator (whichever you prefer to call it) and the gearcase, which caused the two rub together badly. It's hard for me to get parts for this machine here in Canada, so I would much prefer to make a new spacer if I could find the dimensions.
Second problem is that the rear clutch seems to stick open from time to time. I've taken it apart and cleaned multiple times, and re-greased, but that doesn't seem to be a permanent fix. Seems to only stick open a little, and once the clutch is in my hands, and slight twist and I'll pop close, and move smoothly as can be in my hands. Not sure if there's something I'm missing when I take it apart. I'm not 100% sure if it's even the original rear clutch to the machine.
Third problem being a very bad belt/clutch vibration, which gets worse with speed, until completely and suddenly disappearing around 80 km/hr. I believe that to be a combination of the rear/driven clutch possibly sticking, the front variator being worn badly, and also maybe a worn belt.
Forth issue is that front variator, looks like they're metal plated, but mine has worn through that plating in places, which I assume is normal for after a long period of time.
I took some pictures of the clutches/variator.
Sorry for the long post. I

 

So I've been doing some searching, and I think I found a source for a new variator from the US, should be cheaper for me then buying from the Europe.
I haven't been able to find any dimensions of the spacer I'm missing. I'm just not sure how the clutch should be on the shaft, if there's supposed to be no "float" back and forth on the shaft once the drum is tightened up, I should be able to estimate the spacer width.

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It's an original Piaggio clutch as far as I can tell, but may be originally from a slightly different model. That nut just let's you remove the rear face.
I did have it all apart, and had the pins out, multiple times. Seems to work good for a while, then sticks again. Almost seems like it sticks more when hot, maybe I used the wrong grease.
I ordered a new front pulley, and new belt last night. Still need to build a spacer for the rear pulley and stop it from sticking, but I think all that will take care of my problems.

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I'm pretty sure there should be an encased needle type bearing in the rear of the driven clutch pulley. If that has collapsed it could be causing the end float that you describe.
I have known them to go on peugeot scooters, rips the belt to shreds eventually when it gets really bad.
If the clutch isn't opening/closing fully all the time, the torsion spring could have become weak with age, cheap enough to replace with a new one.

 

There's two sealed ball bearings in the rear pulley, but it seems like there should be a spacer behind the pulley,which would go between the gearcase bearing (another sealed ball bearing), and the rear bearing of the pulley. Spacer would just have to be of a diameter just to contact each inner bearing race.
The new malossi variator I ordered comes with a new spring, I was planning on putting it in anyway.

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So I'm still having issues. Replaced the front pulley that was worn, with a new Malossi one, and replaced the belt. I couldn't install the new spring that came with the kit, as it was to small of a diameter, which leads me to believe that the rear pulley is not original to my scoot, even tho it's stamped with the Piaggio logo. I used the 8 gram weights that came with the kit as well.

I'm still having the belt vibration, at least I assume it's belt vibration. It's barely noticeable at lower speeds, but gets worse with speed, the scooter struggles to hit 80km/hr, then suddenly all vibration is gone and the scooter goes up to 85km/hr with ease. The vibration disappears so suddenly, and there's such a drastic decrease in noise and vibration, the first time it happened I thought the motor quit.

I also installed shims behind the rear pulley, just enough to remove the "float" the pulley had in and out on the shaft.
Here's pictures of the shims, and the front pulley/variator, in case someone spots something I may have missed.

 

LOOK AT THE DAMAGE ON THE REAR OF THE CLUTCH PULLEY!!!!
Small wonder you have vibration. That's shagged.
I can see the gap around the bearing from here.
I've never seen a clutch rear like it.
Think you'd best find a new/replacement one double quick, and chuck that one in the nearest bin.

 

That picture angle makes it look look way worse. The gap you see is the flat spots on the threaded portion on the end of the pulley, the rear pulley face is held on by a nut. Bearing sits in there tight. If you look up in the post you'll see a better pic of the backside of the rear pulley, only difference now is that I changed the bearings in the pulley since then.

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Here's a better picture of the backside of the rear pulley. As you can see the bearing sits in there fine.


I still don't know where to go with the vibration issue. Maybe it's not even a belt issue, but something else completely different, but I don't know what else would cause it to suddenly snap out of the vibration.
I hate to spend all the money on a new rear pulley, and still have the problem.