Some patches don't play

I put some new patches into my GP-100 guitar effects processor by sending it sysex data and everything works just fine - but only from the headphone outlet on the front.

Updated patches are the only ones showing any level at my MOTU Traveler Interface. Choose a factory patch that I didn't touch (except to transmit it to the unit with the others) and there's no level. 

Put the headphones back in the front panel and they all work. I checked to make sure a 'Volume OFF' message wasn't sent without my knowledge by looking at the level in the patch editor, everything is fine there.

Why would it not be sending level to the analog OUTs on select patches but sending level to the headphone jack from all patches?

Thanks - rev