Bill,
We've had some issues with the resistors needing to be bigger than the supplied ones when on a 540. We honestly don't know why the 540's are different, but it works.
If he already has the 33K resistors installed, then try moving up to 100K (actual value isn't critical, anything you find at radioshack is fine). Your mention of "all over the place" on the RPM reading is the common problem that is fixed by the bigger resistors. I believe this is covered in our latest install manuals, but earlier ones were missing it.
If the readings are just off by a fixed ratio, but are stable, then that's a software setting of the pulses per revolution.