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Windows says the total space on the Nuvi drive is  2.78 GB and I have almost all of that  (2.62 gb)now that City Nav  and the topo map are gone, so it is clearly not a problem with insuff. disk space. The Nuvi had City Nav 2011.2  and a topo pre-installed. I was eligible for a free update to 2011.3 so I went for it but the Garmin updater app crashed. Garmin sent me a DVD disk which I used to update the City Nav 2008 on my PC but after that update the version on my Nuvi was regressed back to 2011.1 I had backed up 2011.2 and figured I vould just restore it. So I deleted 2011.1 and tried to copy the backed up 2011.2. That is when I discovered I could not copy anything bigger than 40 mb to the Nuvi without getting the I/O error. But I had 2011.1 on my desktop and had no trouble installing it to the SD card so at least I have a functioning GPS.

Thanks for the replies. I have had good success  building the correct url  manually.

I have new refurbished Nuvi 500. I am getting "Device I/O Errors" whenever I try to load any mapset larger than about 40 mb. THis occurs with Mapsource, MapInstall and Windows Explorer. Most of this was with my desktop running Win XP SP3. When I tried it with my netbook running Widows 7 starter it immediately said I had a disk problem and suggested I let chkdsk run. I did and it found a bad file but no fix of the problem. So I ran a full disk check which was negative. I then defragged and it said the drived was badly fragmented but after runnibg no fragments, However, mapset transfers larger than 40 mb still fail with the same error message.

I am thinking that my Nuvi flash drive is bad and I should return it. Any other ideas? I have loaded all of Cith Nav 2011 to a sd card and the unit works fine But I want to be able to have full use plus am concerned the internal drive will develop more problems later.

The southcentral topo with installer is shown as only 616Mb.

My mistake, I believe it was actually the Southeast US at 782 mb. that failed.
Anyway, last night I successfully downloaded and have installed your US Planimetric - South Central Map. This is an awesome supplement to City Nav, it is great to be able to see the streams and lakes. Plus the historical sites are more accurate. Great work, thanks!

OZ is essentially without internet service for awhile..
Set you clock, get up for a few minutes and start the download at 2AM Saturday.
There are individual State topo maps available for all those States.

Thanks. I actually tried that already. I only got about 700 mb of the 800 mb file before 7:00 am pumpkin time. I tried a resume the following night and got the rest but it was corrupted. One advantage of the dl manager is it splits the file into multiple parts and does a simultaneous dl, then puts then back together, cutting dl time.

Will try the manager again tonight, this time manually inserting the true url.

I have a satellite connection with a 200 MB/day limit. However download limits do not apply from 2:00 am to 7:00 am and the ISP offers a download manager  which allows users to schedule downloads during this unrestricted zone. However the site uses PHP scripts to initiate the downloads
rather than posting the actual file URLs. Sometimes when I try to schedule a download what I actually get is only the html file containing the PHP script, other times it works.
I have sucessfully downloaded :
291-7864-Shenipsit.kmz
379-6238-louisiana_ci2010_install.exe
53-3615-My_Trails_install.exe

but 102-1861-sctopo_install.exe has failed twice.

Does anyone know why some files will download and others do not?

Thanks