I'm back with my final report.
I determined that IC404 wasn't putting out the correct voltages so I opted to try replacing it. Before doing so I checked everything around it one last time and found the fusing resistor R415 to be way out of spec. Supposed to be 22 ohms and it had around 230ohms. I went to get a replacement but couldn't fit it in 1/4w, so had to get it in 1/3w instead.
After replacing those two parts, I put the board back in the machine and flicked on the power. Black screen, no high voltage sizzle in the screen, and the HOT was back to repetitive clicking.
Anticipating that this might not solve the problem, while ordering those parts I also ordered a bunch of other parts that could be the problem, along with spares of commonly reported failed components. Since my first attempt didn't work, I figured I may as well toss all these parts in, and then I'd know for sure that A) one of those parts was the issue, or B) none of those parts were the issue but at least I'd know they were all new.
I tested each old part as I removed it, just to see if there was anything amiss. Here's what I replaced:
IC401
IC402
IC803 - Test result said "unknown part". I assume that means it was dead.
IC805
IC806 - Test result said "unknown part". I assume that means it was dead.
C810 - This part was already new, but the troubleshooting guide said to replace it with a 270uf 35v cap instead of the 220uf if you have issues, so I did.
Q402 and Q401 - test result was a little off compared to Q402
Q426 and Q427
Q413 and Q407 - test result was a little off compared to Q413
Q105, Q403, Q405, Q412, Q419, Q423, Q428
After changing all of those, I turned it on aaaaaaand....we're back to the same condition. No improvement.
And with that, I give up.
I've been banging my head against this wall for long enough
.
This D9200 is a real piece of work! I've been trying to fix this thing for months and it sounds like these have a history of being great when they work and being a nightmare when they don't. I've only experienced the latter so in my limited experience I'm calling this thing a piece of junk!
I've found an alternate solution. I came across a free 27" Toshiba 27AFX55 TV on kijiji. I went and picked it up and it works great. Absolutely nothing wrong with it. This series of TV's is well documented on how to do an RGB input mod, so that's what I'm going to do and then shove it into the cabinet. I do get a slight downgrade in resolution quality because the Big Buck Hunter game board outputted medium resolution, but this tv will only do standard resolution. I never really got to see the D9200 run for more than 5 minutes, so I'll never know what I was missing anyways. I can set the game board to run in standard resolution.
Here's some photos of the new TV running some tests. First one was me learning that I can't run the game in medium resolution (31.5khz) on a consumer TV that can only do 15khz. Second photo is of my PS1 hooked up with an RGB scart cable to the component input. Looks pretty sharp to me. Photos don't do it justice.
Thanks to everyone that attempted to help!
It was a long road to get here, but unfortunately we'll have to toss this thread into the every-growing category of D9200 repair failures.