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more than likely you have a bad PU selector switch. those things go bad often. i would have that examined and then see if the problem persists
 
The first thing you mentioned happens with my EMG's as well.. if they're in the middle position you have to have a little bit of volume on BOTH for them to activate.

The second does not happen for me.
 
i used to do EMG PU installs on many guitars and i remember making a mistake with the volume pots once, where it would sort of go thru the volume after the switch if that makes sense. effectively, if both pu's were selected but one volume was down, neither would work because both volumes sort of worked as a independant master. i would check your EMG wiring diagram and see if it matches the one specifically for LP's or guitars with two sets of volume/tone controls. the difference is literally switching two wires on each of the volume pots.
 

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