New 6HP Tohatsu Sail Drive Stalling

Kill switch connection intermittantly shorting?
The symptoms from the OP don't make me think towards that: "There's always a subtle tell-tale before it quits, sounding like it's hesitating a little, makes me think it's starved for gas.", and "When hearing the telltale sound of the engine bogging down, I've been able to keep in running for a couple more minutes by pressing the priming bulb, but it still failed".
I hope that Canada thaws soon... (y) .
 
Even if fuel can be drawn from both tanks this should not cause flooding of the carb.

No, but we can imagine several ways the fuel from the external tank could be inadvertently pressurized. If you were Canadian and filled up the external tank in -40degs and then used it in direct sunlight on a sunny +10degs day. Or if the fuel bulb got pumped by an enthusiastic helper, or someone sat on the external tank and gave it a squeeze. (Of course the air screw on the external tank would need to be closed for some of those mechanisms, but do we all remember every time?)

If there was enough pressure to fill the internal tank from the external tank then I am sure that would push fuel past the needle valve, only the buoyancy of the float is holding it closed.

Either way, Steve_N wins post of the week IMHO for coming up with a cunning theory that explains everything, whether that theory turns out to be right or wrong.
 
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