If a piece of software is not performing as you want it, the first thing to ask is if you're using it the right way
1) It definitely is not RANDOMLY opening different methods! If you open a single datafile, you can specify which method to open: The original acquisition method, the method used to create the last results or the present method (i.e. don't open a method at all). If you're using result sets, of course it opens the respective result set method, that's how it's supposed to work.
2) If you're processing a bunch of a data in the result set mode, of course you can select a printer. If you want to print a single piece of data, you have to manually select the printer in advance
3) Because it's set in the printer configuration?
4) Basically because everytime you change anything in the method, it needs to be saved for tracibility reasons (21 CFR...). Unfortunately, the printer setting is part of the method...I admit that one is really not very smart.
What is so bad about the reporting? Basic reporting was fine for me in the past, I didn't have the time to really delve into the intelligent reporting capabilities yet.
Did you adress your issues to Agilent? That would be the first thing to do, if they can't help you, THEN it's time to shout your frustration to the world.
If you don't use the result set mode yet, I'd strongly suggest to consider using it.