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Wiring diagram for honda northstar 5500 IPG

No continuity on my GFI circuitry

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Hi, Riley the answer to this question is way above my pay grade for this situation, I would call or visit my local dealer or reputable shop's service/parts department and inquire about any possible quick fix, answers, or parts inquiry.
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Stator is contacting the rotor, did you replace both bearings? remove the stator and look for damage on the stator and rotor laminates

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Hi, Anonymous first check for continuity at the power and ground wire at the horn, then check for continuity at the horn button, back in the day there was a small adjustment screw on the back of the horn, by turning it one way or the other you could set the limit on how much the diaphragm vibrated.
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wire a 120v 15a to 9vdc or 12vdc battery make sure you have no voltage out of the 240 side. with the unit running plug into the 120v receptacl QUICKLY pull out. check power out put. if it did'nt work check your battery, than do it again twice as long. you must check all component before doing this to make sure you don't have any other fail-er. this is danger-us be careful. good luck

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If you have checked the stator, rotor and brushes and they appear alright then it is probably a voltage regulator. The honda dealer can run a test and confirm the problem at very little expense. It cost me 25 dollars Canadian to preform the test and it was well worth the money because you cannot return electrical parts and they can be very expensive. Have a great day!
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There are a few scenarios that can cause this.

1) The extension cord that you are using is too long / too light of a guage. Try a heavier extension cord, or plug directly into the generator.

2) The alternator has lost its "residual magnetism" and may need to be reflashed. Consult Northstar for instructions and details.

3) The voltage regulator (actually a simple capacitor) may be "weak"

4) The diode for field winding may be bad.

You can get a copy of your manual here, page 40 has diagram and part numbers.

http://www.northerntool.com/downloads/manuals/165911.pdf?cm_ven=natural&cm_cat=netconcepts&cm_pla=Google&cm_ite=http%3A%2F%2Fwww.google.com%2F%26

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