It seems I can only do a hotsync after a warm reset (holding up arrow and resetting etc.). After I do a regular reset, I can't hotsync. I have to warm reset again and then I can hotsync. Anyone seen this?
Nope. Sounds like you have a rogue app in there somewhere. What have you changed since it last worked?
Palm Pilot Personal -> Palm III -> Palm IIIx -> Visor Prism -> Clie TJ37 -> Treo 650 -> GSM Centro