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I did end up blocking off the bypass. I had good and not what I wanted effects. The good was during the winter the heat seemed to do better. All the air was directed through the heater core which helps. During the summer with the heat cut off (the flap is closed against the heater core) there...

Okay, I have really look this over now. It appears to be designed to allow air flow from the outside even when all levers are in the off position. It appears that the air will flow around the heater core when the heat is off and when you cut the heat on the flap closes that fresh air bypass...

Okay took the one off my parts truck. So the flap in the second picture is supposed to have foam on it to seal off the air flow when closed, correct? Mine doesn't have any foam in it anywhere but all flaps seems to working correctly when you move the levers.

Did that stop the bleeding trough air when the vents were in the closed off position?

Does the fresh air that comes in from the cowl at the windshield go through the heater core? I was thinking of taking off the cowl and sealing / covering the fresh air holes. Has anyone done this? What are the down sides?

Thanks. I was worried that was the case.

Did anyone ever find a solution to this? My M1009 is blowing hot air through the floor vent, stronger flow the faster your drive, event with all the heat controls turned to the off position. It's 90 some degrees outside and the heat is killing me.