Is this happening on the pump's lower speed and how long does it take to see a bubble form after fully priming?
Also did you actually see air bubbles coming into the pump from the suction side pipe? If so, it could be a leak in any valves or pipe upstream from that.
On another note, many owners of two speed and VS pumps on lower speeds have experienced the same thing including myself. I have a few theories on this and depending how quickly the air forms, it could be either a very slow leak in the pump lid since they tend to seal better at high suction or it could be a slow outgassing of dissolved air in the water. In my own case, I believe it to be outgassing as I can see the tiny bubbles forming on the pump basket surface. When pumps run slow, they do not have enough flow rate to expell any air in the pump basket so it tends to accumulate for whatever reason. So many VS owners find they need a certain high speed run time per day in order to flush out the accumulated air.
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