This paper deals with the design and no load test of an outer rotor Permanent Magnet Synchronous Generator (PMSG). For this purpose, many analyses were made to identify which modification of the geometrical parameters help us to improve the voltage waveform in winding terminals of the generator. Tests results complements previous works where were presented analysis of this 5 kW PMSG. The Total Harmonic Distortion (THD) is analyzed, under design parameters handling, i.e., the geometry of the stator, the polar arc percentage, the air gap, the skew angle in rotor poles, the pole length and the core steel class. Seventy-six cases are simulated and the results provide useful information for designing these machines. Tests on machine help us to verify the electromagnetic analysis. Finally, some important stages of the generator building process are shown.