Seth Green's Leo voice did seem a bit off in the Northampton arc but once they got back to New York he sounded fine. After that he also made his voice a bit higher pitched to fit Leonardo's character better and it worked.
As for other TMNT series, they generally filled the non-Shredder episodes with generic human enemies, robots, or aliens...so its not much different from a lot of mutants like what Nick did. The 2k3 series did add a ton of mutants as it progressed but they were mostly treated as mindless monsters without any character and they didn't speak. The only notable exception of course being Leatherhead who was a major character and the Turtles friend like this series.
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