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Well - to eliminate Sonar from the equation - you can export the MIDI stuff to a midi file - and load the SF's into KX manually in the KX Sound Font manager - and see of they play correctly in winamp (using KX synth X) for midi INPUT device - or setup windows to use KX Synth as default MIDI device and play it in windows media player.
edit: Just make sure the saved midi file will use MIDI PORT 0 or one - in other words don't have mutiple midiports used and make sure they are the first midi port you have configured in sonar - this was a problem in older sonar versions.
I would try winamp, becuase you can set up is a reset is to be sent between tracks or not:
Winamp: Options > Preferences > Plug Ins >INPUT > Nullsoft Midi player > Configure > MIDI extensions Dropdown - try None and GM.
Oh also - I notice (because I have the 'Platinum') the IR remote control will send SYSEX thru the KX Control Midi port - This is prolly irrelevant to you.. maybe ?? - I thought the EX had IR remotes too ?) , but now... I also wonder if those 2 midi ports are interacting for you.
Are you also using KX Automation as well ?
If not, that may be a work around for you - set up KX router to use more FXBuss lines for KX synths - and insert PAN plug ins in the KX DSP - and use KX Automation to control the panning instead of MID CC#10 as mpst would normally.
To make this easier in sonar; You can convert Midi CC's # to another CC# with the EDIT > INTERPOLATE or with CAL (But not all versions of Sonar has this ability - which seems to have been dropped with Sonar 6, hmm - not real popular, but was quite useful in the past for me for such things)
Also - it also sounds like you may have a compressor, or dynamics processor in line with the KXSynths in the KX DSP - I have had that 'loud' initial volume - until the attack of the compressor lowered the volume - this can happen for heavy compression - when we want to raise low volume, but lower high volume inputs to the compressor.
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