Bypass sending a full range signal to the mains even when they are set to small, and no sub output whatsoever would just make me happier than a clam

To me, you have a 2 channel source coming in. When in bypass, don't mess with it. Don't apply any type of filter. Don't duplicate it and route a signal to the sub. Don't do anything with it. Just send the most direct signal possible straight from the 2 channel input, to the main's output.

Now my 990 has started sending a signal to the sub no matter what sound field it is on or what size the front speakers are set on. IE when I am listening to a CD and I have it set to "bypass" and only the L and R are lit up on the 990 display, a signal is still being sent to the subs even though according to the display the sub is not being used.

Is outlaw going to offer any help?

Have you checked to make sure your sub/spk size have not changed to LG/LR+SUB? According to the both the digital and analog input bass management matrices using this setting will output bass to the sub in all playback modes.

Yeah, that sounds weird. It sounds like it just started happening. Did as mm_half3 suggests, did something change recently?

The standard Outlaw answer in these cases is to reload the firmware. Although I get somewhat tired of that answer, I would probably suggest it in this case. You might as well, as you won't get anywhere with official Outlaw help until you do.

Even with sub set to off a sub signal is still sent out. I tried with speakers on lg/sm and with sub on off/LFE only/LF+sub(obviously this one will always send a signal)

It has been awhile and now its awhile longer. Is this issue being looked at and if so when can we expect a fix? This issue was found in April, does it take this long to do an estimate?

Personally, I'm pretty frustrated with how Outlaw has dealt with this issue. I mean, a little communication goes a long way. It seems to me that they are trying to ignore it and hope it will go away. Earlier, I felt that a little patience would be rewarded. Now I feel that I should have sold the 990 earlier. Live and learn I guess...

Has anyone heard from Outlaw on this?

Not me. Unfortunately, it's become apparent that they have bigger fish to fry...

Me neither. At least they still have my support ticket left open. If it would've magically closed and disappeared, I'd be even more worried.