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It appears that your generator is configured for 240/416, since within a small tolerance, that's what you're getting. It needs to be reconfigured for 120/208, but sewerzuk or someone else who has experience with that unit will have to explain. After that, you'll be getting 120 from each leg to...
I like to put a layer of grease in the joint when reassembling after cleaning. It keeps water and acid fumes out and makes the connection more reliable.
As I understand it, the MEP-004A can be configured for 120/208 3 phase operation. When it is, each leg is 120V to neutral, and it's 208V between legs. If you connect two legs to your two 120V house inputs, and neutral to your house neutral, you'll have 120V at all your 120V outlets, and 208 on...
I came across a thread on Smokstak about US Motors, with some clues about the current status of the company: http://www.smokstak.com/forum/showthread.php?t=14900
Also, there appears to be a German manual on it...
If it makes you feel better, I don't leave tools on my MEP-003A while it's running for the same reason, and four cylinder engines are inherently smoother running than two cylinder engines.
Frequency can't change if the RPM does not change, because they're tied together. The four-pole alternator is directly coupled to the engine, so you get exactly 60 Hz AC when the engine is running at 1800 RPM. If the AC frequency is changing, then the engine speed is changing.
Just a shot in the dark, but starting with the simple things, a bad ignition condenser could cause very weak spark. Dirty or pitted points could also.
I don't know how many models of Wico mags there are, but I've gotten them cheaply for my Gravely mower from eBay. Maybe if something in there...
No tax if they're being purchased for resale, if you do it properly, but I still have a hard time with the numbers. I don't have a hard time with the idea behind it though... helping others get a good product that's hard to find.