I've had similar problems....
I just installed an ST4000+ about 3 weeks ago. There were 2 things wrong with it, one of which is fixed. I can't get the Autopilot compass to agree with the boat's compass on all headings. From 90 degrees to about 180 it's off by between 10 & 15 degrees. I can't seem to reconcile it, even though the deviation value is within the proper limits. I'm still working on that one.The other problem I fixed. I used to have a perfect course when heading northerly, but it would "hunt" for the proper course on a southerly track. This was fixed by doing 2 things:1. Install the compass under the steps leading from the cockpit so that it was facing forward. My previous location, on the port bulkhead in the quarterberth (only about 3' away from the permanent location) was too close to a magnetic field, probably caused by the engine wiring harness going to the instrument panel via the port lazarette. The new location gives a deviation value of 8. You want the compass to be as close as possible to the waterline, and as close as possible to the center line of the boat with a minimal magnetic field. Every boat is different, so you'll have to find yours.2. Adjust the calibration settings. These are the values that worked best for me. I don't have the rudder sensor, but it now seems to hold a very good course (+/- 3 degrees, even in a chop). Try these out:1. Rudder Gain = 22. Response = 13. AutoTrim = 24. AutoAdapt = North5. Cruise Sp = 66. Variation = 15 East (it should be different for you, I'm in Boston)If you're like me, you've tried a million different combinations of things to try to get it to work. If that's the case, I recommend you start over by resetting the unit to the default levels (page 98 of the manual), swinging the boat's compass & getting a new deviation level. Next, turn on your GPS or Loran, if you have it. The autopilot uses this information to help calibrate the AutoAdapt function. If you don't have a GPS or Loran hooked up, then set your Latitude to your position. Try the default settings above & hopefully it will work.I hope this helps...give me an email at allens@mathworks.com if you need more help, ok? Believe me, it's WELL WORTH the frustration to get it working. I love it & I'm really impressed with it's ability to hold a course, even in varying winds and following seas.Good Luck!Allen Schweitzers/v DrambuieC-30, Hull# 632