Hahah, my first post on GearSlutz, so let's try this.
I just got an used DX7S so I'm also trying to figure this thing out. If you have the cartridge it's easy, you just follow
this guide and you should be fine.
If you don't have the cartridge than you can try to find some patches only. I've used tons of DX7 patches and they all seem to work fine so a google search should get you tons of those.
This is what I do here and it works just fine: set Internal Prot to off, click on Voice and click on 01. (Make sure you're on the INT voices and not the ones on the CRT) Make sure midi cables are properly connected. Open the sysex file using Sysex Librarian, pick the Midi Interface and double click the bank in order to send it to the DX7S.
Two things I noticed while doing this:
1 - Bank files have pretty much the same size I thing: 4k
2 - Once you send the bank it won't automatically go to the first voice on the new bank but it'll stay on whatever it was. In order to use the transferred bank you must choose another voice in order to start using your new bank.
Hope you can get it to work