Thanks, guys. I have a CS education and worked as a PC tech in the early-mid 90s so I'm comfortable with this hardware from a conceptual POV, but have no practical domain expertise. I especially appreciated the service manual link, it clears up the lack of options.
I think the plan at this point is to back it up and do a full reset, test it, if it still fails then crack it open, blow it out with air and wiggle all the connectors. I doubt very much any of those things will help, but it's possible in my mind that something unlikely, such as a moist dust bunny in the wrong place, is responsible for this.
If that doesn't work out, I'm going to be sad. I rather like that piano, and don't really want to replace it. I'll try and get an estimate out of the local Yamaha factory guy, but I definitely don't want to drop, say, $500 on a piano I can functionally replace for about $800 (DGX 640).
the_big_e - I feel your pain, replacing a piano that you use for more than piano and rhodes voices means changing your sound. I have a bunch of dual-voice / split programs in this thing that will only "load" on either a DGX-620 or DGX-520. Changing sounds sucks, because I can often burn 6-8 hours auditioning patches and tweaking settings; then sometimes you have to alter your playing style for a tune to get the synth or string patches to do what you're after.
I went through this a number of years ago with a PSR-510; again, not a particularly great piano, but it had a bunch of neat patches that I wove into "my sound". I don't even play in that band any more and I'm still keeping an eye out for a cheap one..
Hey, Can you MIDI up your EX7? My PSR-510 has an option "Local On" which makes a midi keyboard behave as the internal keyboard; this way I can use a generic controller plus the PSR-510's buttons to get what I want...but it's too bulky in that state for stage work IMO.
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Hammond: BC, M3, Split L111, L122 / Leslie: 51, 760 / Yamaha: DGX-620, PF-85
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Dr. Bombay! We're going to be organasmic!