Could be a bad breaker, A blown fuse on the generator (would be wired into the wiring of the alternator and taped up), bad connection on generator wiring or faulty generator wire. You may or may not need to replace the generator assembly.
SOURCE: Honda EM 2500 Generator
I posted a general tutorial on troubleshooting this problem here.
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Carl
SOURCE: Honda ems 4000 generator starts and runs great, but no power
At the controller, you need to see if it is actually sending electricity out of the Generator/Alternator, have a look where the leads from the power making unit mates, (Think of it as a motor in reverse) onto the board. There should be an AC Voltage there, then, work back, or out from there, trace the Voltage until it stops, thats the problem... Check the Breaker isn't tripped or faulty too.
SOURCE: black max 7kw generator high voltage output
Those voltage readings MAY be normal.
The AC waveform may cause your meter to read inaccurately. You would need to use a TRUE RMS meter to accurately read the voltage.
The siple meters actually read the AVERAGE voltage and then are calibrated to mulltiply it by the "form factor" for a sine wave. OFTEN these generators don't produce a clean sine wave. A square-ish wave will read higher on the garden variety meters.
Compare the brightness of a lamp comparing to when run on your utility.
The frequency depends on engine speed ... yours is running a bit fast...check it under at least half load and if off, adjust the govenor slightly.
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SOURCE: Honda ems 4000 generator starts and runs great, but no power
The plunger is stuck where the governor rod which is spring attached to the frame is. If you locate the governor metal rod on the lower level of the unit. zrock it to a higher rpm as you would a car carburator from under the hood.
This will free the plunger and the green light will go on and your current meter will register 120 volts.
When you lay up the generator for quite some time it often sticks closed. With monthly start up you will no have this problem reoccurr.
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