Andy,
Losses are to be expected when using dichros to combine different color lasers. Also, you will be loosing a few more percent from each mirror on the x-y scan head. The type of losses you are talking about are way too high. Looking at the photo of your projector, I am a bit puzzled by the optic you seem to be refering to as a "dichro". I'm not quite sure what that is. Here is what a dichro looks like:
They could also be square in shape and much thinner. You may just want to get rid of that optic and replace it will a good quality optic from Edmunds.
You may also want to add an IR filter for safety...
David