I noticed when I put the cotter pins back in the adjustment arm to the commutator that when the spark advance lever is moved, the commutator doesn't start moving until the lever gets down several notches. Is that because the tension arm is too tight or is there some other reason?

Wayne,check down at the bottom of the spark rod,the one that runs from the steering wheel down to below the steering gear bracket. I suspect that the little lever that is pinned to it is loose.Have somebody work it up and down while you watch.Things just being bent in general can cause this,too.

Wayne, you could have some slack in the arms and the rod, they sometimes get worn pretty badly. A little here and there adds up pretty quick. Dave