Now I have to adjust the volume to a considerably higher setting to get the same output. Sometimes I go to -10dB... sometimes even closer to 0, (for a very short time if my wife isn't home). Different sources, SAT/Bluray/Music, are clearly different levels.
As ADTG explained, check your Audyssey settings, depending on what it has to do with your sub it could have trim the other 5 speakers down to maintain a better balance.
Settings in the X4000 seem to limit volume to 0dB max. So I couldn't go to +anything if I wanted to.
Did you buy it brand new in the box? According to Owner's manual page 156, the default setting is "Off", that means no limit and it should go up to +18dB. It looks like somehow you have the volume limit set to "0". If that is the case, just set it back to "Off".
1) Is it unusual for a setting, (say -10dB), to be noticeably louder on one system than another... particularaly when it's louder on the system w/ less power?
ADTG mentioned one possible reason, I would add that if Audyssey did trim the levels down by 3 to 6 dB and you don't like that, you should lower the subwoofer's volume and run Audyssey again. If you increase the trim levels manually then to maintain the proper balance you will have to increase the sub's trim level by the same amount and that is not a good idea. I highly recommend you read Audyssey 101. Or at least read about speaker trim levels I pasted below.
Speaker Trim Levels
Chris Kyriakakis September 29, 2012
Trim levels are just relative numbers. There is nothing wrong (or different) about negative trims. The point of calibrating levels is to (1) achieve the same level for every speaker and (2) play at film reference when the master volume is at 0.
If the speakers have high sensitivity, or are close to the listening position (or both) then the trim levels will show up negative to achieve the goals mentioned above. It's not a good idea to change the trims because that will throw off the Dynamic EQ calibration. If you want the system to play louder just turn up the master volume.
SPL meters need calibration so it's possible that there is enough discrepancy between the meter and the Audyssey mic to show different readings. Also, the internal test noise of the AVR is a slightly different way of calculating level than what Audyssey does using psychoacoustic weighting of the measured response.
In any case, it's not a huge deal to change the trims if you feel the need to (keeping in mind the implications on Dynamic EQ). The most important part of Audyssey--the filters--are not affected by trim levels.
2) Does my X4000 really max out at 0dB?
The way you describe it, that even if you try to turn it up further it remains at 0, then I would say the volume limit is "On" but you can set it to "Off" then you can go pass 0.
(BTW, the system sound is superb! I have no issue w/ the sound quality. And frankly doubt I would ever go louder than I do now, even if I could. I just sort of expected this system would go WAY louder than it does.)
I would still set volume limit to "Off" for peace of mind but agree, stay well below that point or you risk damaging your hearing. If -10 sounds loud enough for you, that's good, the lower the better. I keep mine at around -20 most of the time but it depends on your speaker sensitivities, room acoustics and other factors. Did you check the spl with a spl meter?