I've tried everything I can think of now. I moved the lot entirely which added him to the household. So while he was living there (under my control) I had a roommate move in I didn't know or request. So I moved him into another lot again and asked him to room again. Since the move, I've had 3 uninvited roommates come and cancel his roommate status, while he remained at the house. I've had to dismiss them all, move him out and go through the request with him each time. This is very frustrating. My sim gave him a motive mobile as a gift so at least when he goes home, he's revved up.
He still won't leave the new lot on his own. I'm not getting the stuck here bubble over his head but he never walks to the edge of the lot as if leaving. He does nothing but putters around the place. He also won't go to work now. My sim must get him off the lot via "go here with". As soon as he steps off, he gets into the motive mobile and goes on his own.
Also, he won't go to bed until he is fainting from exhaustion.
later...I've figured out the problem. The stereo. I had it upgraded to wire house, so I've changed it to improved speakers and make sure it's off unless both can use it ;ie exercising. He now sleeps and leaves the property as he should (albeit only for a games hour or so - then returns home unless my sim is keeping him entertained).
Note to self - watch the stereo.