A client was recently trying to copy a 5Gb Outlook PST (mail) file to an empty standard 16Gb memory stick but was unable to do so as Windows reported that the file was too large.
When seeing this error message most people logically assume that the message is telling them the file is too big to fit on the stick, even though they know it should be fine. The error message does actually indicate the problem. It is not the size of the stick but the format of the file system used on the stick.
Most memory sticks on the market are formatted using a FAT32 system (ie; the pattern and format in which data is written on the stick). FAT32 has been around for a long time and has a file size limitation. In short, it cannot handle files greater than 4Gb.
The solution is to reformat the memory stick using an NTFS system. Once that is done the large file will copy to it without any problems.
To achieve this:
Open Disk Drives in the right pane
Find your memory stick
Right Click and select Properties
Change it from Quick Removal to Better Performance
(Note: the requirement about Safely Removing Hardware)
You can now close the Manage windows.
Open Computer again
Locate your Memory Stick
Right Click on it
Select Format and choose the NTFS filesystem from the drop down
When complete you will be able to use it for files greater than 4Gb in size.