Ive already tried all of that, cloned the original sector by sector, different formats, creating partitions etc its a non runner unfortunately. The unit sees through it all and refuses to play.
2GB card arrived. Worked first go. I can even populate the card directly on a usb adaptor. This is quicker than having to have the unit plugged into pc and copying directly that way.
Card from China has gone walkies somewhere in customs. Ordered another one for a fiver off Ebay which is what I should have done first off.
No worries. My son in law has asked to borrow it later on in the year for Spain so should get some use out of it. Just waiting for adaptor now for antenna for better reception.

Dinosaur

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Thanks to all for help and advice