FAT32 partition sizes are limited to 32GB in size using the native format command under Windows 2000 and Windows XP. (The maximum size is 127.5 GB practical and 2TB standard theoretical.).When attempting to format a FAT32 partition larger than 32 GB, the format fails near the end of the process with the following error:
Logical Disk Manager: Volume size too big.
This limitation is documented in MS Article 314463.
As a workaround, you should boot using Windows 98 or Linux and format the disk or download mkdosfs from here and launch it with these options:
c:\>mkdosfs -v -F 32 -n volname X:
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