Quote Originally Posted by Neil View Post
How big is the 41 bin file? It should be 4,352 KB and although it is encrypted it should 'copy & paste' normally.
Yes, the size is 4,352 KB. With your advice of post #16 in mind, refreshed by post #125, I tried a third card. A Kingston 4 GB microSD brand new from a sealed package. The process again froze on the Garmin splash screen with the text "Loading Maps" at the bottom of the screen.

So I decided to now use another brand and capacity: a 2 GB Transcend microSD. And voilá: the backup was made in seconds without any corrupted files on the microSD! Amazing how particular the combination of a memory card with a specific unit can be.