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Jazon,
I pulled the lower unit this weekend and replaced all of the rubber barrel seals around the intake water pipe and the water pipe running up the leg in an effort to ensure its getting water up to the powerhead. When I blow compressed air into the water pipe from the bottom( with the lower unit removed) I can feel a little bit of air coming out from the tell tale, but it seems like a lot is escaping into the leg. The seal at the top of water pipe feels good. Meaning when I stick the long water pipe back into its home at the top of the leg the seal seems to hold it pretty well.
Based on the sound of air escaping into the chamber of the leg, it seems like there is a leak in cooling system, hence the lack of good flow out the tell tale. Are there any other obvious locations for the pipe to leak besides the rubber grommet/ barrel seal at the top?