Thats for the info guys. Going to pull pump to see what it looks like.

I'm going to try plugging a few holes on the drive. It definatly only happens when I air the boat out. I can run WOT forever and it's fine. It's so incidential, very rough, washing machine like water/high speeds that this happens.
If I had a blockage or scorn pump I would think it would be much more consistant at WOT. I was told that Baja lowered the X on 2005 and later 30 Outlaws. That makes me wonder as well, as mine is an 04.

I understand and frankly I have never heard of this problem before.

If you look at Fountains and other stepped bottom vee hull with very hig "X" dimensions you would expect to be seeing a lot more of this problem.

I'm still with Bobby here in that if the pump is not doing it's job the water is running back when you air the boat out. So you are seeing more of a pressure feed to the engine when running rather than the pump actually pumping and pulling the water up into the drive.

I learned the hard way with my new setup that you CANNOT have any air getting into the system or it will kill you water pressure.

Please keep me posted on what you figure out.

I would bet money that his systems venting somewhere and his seapumps shot if he dont find the air leak he will ruin a new pump been there done that ,when you put the new pump on it seems ok at first the air bubbles score the pump melt the sides of the impeller and its real apperent when running hard not at normal use I have 3 seapumps and about 6 used impellers ,impellers look perfect when you look real close you can see the are melted on the ends

UPDATE:

I did not try plugging holes in drive. I did inspect heat exchanger, backflushed all lines, no blockage. Inspected t-connection and entire fresh water flush system, no leaks, check valve perfect.
Had new sea water pump installed. Old one did have very minor wear marks, impellor had no signs of damage.
After running the boat hard, I could not get the alarm to go off. Now the starboard alarm did go off. Great news as this never happened before, it was always the port, thought the pump was the issue.
Well, now I'm bummed again, just returned from 1,000 islands and the port low water pressue alarm with the new pump installed ended up going off again. Back to the dealer for some more computer scans, but I'm stumped as both engines now have done it.
Again, it only happened when I was airing the boat out. I ran close to WOT most the weekend and things were fine, unless I caught some air or was in really washy/choppy/boat wake water.

take the new pump apart drag your finger nail across the housing if its scorn already your sucking air before the pump the air can wipe out a pump in a few hours of running make sure all hose clamps from transom to sea pump are tight ,also fresh water flush cap is tight and the 90 behind this cap is tight if it drips it is also sucking air

The original pump housing did not having scoring at all. The impellor looked fine. The end plates did however have some minor gouges. Now, all the clamps on the fresh water flush and drive intake hose were and are tight as well as the 90 elbow and black cap on the flush. Since the other engine did it I'm just stumped. That pump was a ***** for the tech at the dealer to remove/install. This Merc dealer is a great facality and a friend. They take their time and it's done right. I don't know if I can put him through it again He suggested bypassing flush all together for now and see if that helps. I would think if the t-connection or any other part of the flush was leaking air, it would do it more often. Bottom line is I'm sucking air and I really think it's from the side holes on the gear casing. Boat air's out, air sucks in, alarm goes off. The question is, what to try next?

I wish Callaway would chime in and let me know what he found out with his. It sounds very similar to my situation.

Thanks for advice Crayola. I really do appreciate it.

Check the T-fitting into the flush system for the fresh water hose hookup. These are known to get filled with silt/sand/crap and restrict water flow at times. I've even seen them installed backwards which is really bad. Stupid thing to go wrong, and last thing you would check, but this will do it. Also, make sure the cap on the end of the fitting where you attach the garden hose is making a tight air tight seal with a good rubber washer.

I posted above that the T-fitting/clamps/cap/washer are all in perfect working order. Thanks for the suggestion though.