I am getting quite suspicious that there is a maximum file size for transfer to flash memory cards on USB.
I have a Casio EM500 PocketPC with WinCE 3.0, a card reader and a digital camera. All three can take SD/MMC cards and I now have 4 of them the 32MB, 64MB and 128MB cards have all been fine.
Recently I bought a 256MB SD card for the PocketPC to watch DVDs on (I use VirtualDub to convert them to fit the small screen). One of the files is 115MB and transfers perfectly. The other is 130MB and every time I try to copy it from my hard drive onto the SD card I error I/O errors and Explorer freezes. Is it because it's >128Mb in size?
Today I replaced the card and this one does exactly the same. Nothing in the MicroSoft website helps.

Anyone else experienced this?