i had a problem similiar to this last week
After i copied a 700mb file to a 2gb usb stick it said there was no space left,
it also denied me any access to the properties of the stick and when i tried deleting the file it would reappear in the window after a few seconds
the only way i could fix it was to format it, it gave me a few errors the first couple of times i tried this but it eventually worked and now its back in good working order
I doubt if there's anything wrong with the drive, as I used it on my desktop without any problems. This evening copied a 8GB file to the disk, and it was spot on the first time....
Install Avast 5 to run it's Boot Scan of all drives. Viruses have no place to hide in a boot scan.
Run Disk Check on all HD's.
Then unplug other HD's and boot maker's diag/repair CD to run full scan: Hard Drive Diagnostics Tools and Utilities (Storage) - TACKtech Corp.URL
Checkdisk gave no errors. Intel SSD Toolbox does not find any issues with the drive.
In the meantime I got a 640GB Dane-elec external 2.5" hd: same issues....
Funny thing is that after the second time I copy the (large) file (copy & replace) it is always good so far....
Just to share my experience...
I always copy big file from pc to external 2.5" hard drive and vice versa, up to 40GB single mkv file. Yes, occasionally USB connection will give error especially continuous copying multiple big files, causing file corrupted and the need of chkdisk to repair disk.
Finally, I switch to eSATA instead of USB2, no problem since then on both XP and Win 7, successful rate 100% after >100 transfers. The external hard drive enclosure i use is VANTEC 2.5" eSATA+USB enclosure pair with WD 320GB SATAII 7200rpm. My desktop is XP Pro SP3 32bit upgraded to AHCI mode which made eSATA hot-swappable, while my notebook is Win 7 Pro 32bit. Both PC have motherboard built-in eSATA port. The major plus point is eSATA gave much faster (2-3x) transfer time over USB2, now i can safely cut and paste thru eSATA, instead of copy and paste thru USB2 and double check file for error.
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