File too big error copying to USB flash drive on my Mac?

I’m baffled. I have a 16GB Kingston USB flash drive that I use on my Mac system and I’m trying to copy a 5GB file onto it. It’s empty. But I keep getting the error “can’t be copied because it’s too large”. What’s wrong and how do I fix it?

I’ve seen this error too and what you’re missing is the critical last few words of the error itself. It actually says “item can’t be copied because it is too large for the volume’s format.” That “for the volume’s format” is critical, because most vendors — Kingston included — ship flash drives with a default format of Windows (FAT). A bit of digging reveals that the max filesize supported on the File Allocation Table (FAT) version of the Windows file system is 4GB. So even if the flash drive has tons and tons of available space, the sad fact is that your file is too big for the file format.

But there’s another possibility that I see a lot of people trip over with flash drives too, even when the files are smaller than 4GB, that you haven’t emptied your trash yet. It works like this: You have an 8GB flash drive. You have 6GB of files on it. You drag them all to the Trash, then check your free space. It’s 1.6GB. What? Empty your Trash and it’ll both empty whatever trashed files you have on the computer itself and the files you’ve dragged to the Trash from your USB flash drive too. Confusing, yes. And it’s true on both Mac and Windows.

Now back to the file too big for the FAT format problem. Here’s the error message you’re probably seeing:

windows-fat-format-limitations
As you can see, if you miss the last few words, you can be baffled how a file can be substantially smaller than the capacity of the thumb drive, but still fail to copy.

To fix it, we’re going to need to reformat the flash drive. That’s done by finding the “Disk Utility” program that’s included with Mac OS X in the “Utilities” folder within the “Applications” folder. It looks like this:

windows-fat-format-limitations
Launch it and you’ll see a list of all drives and devices hooked up to your system:

windows-fat-format-limitations
Be careful here. Pick the right device. Take your time here and make sure that you’ve selected the flash drive, not your main hard drive. Picking the latter would be a complete disaster and you’d hate me forever. So don’t do it.

You can confirm by looking at all the stats at the bottom of the window. Here’s what I see for my Kingston drive:

windows-fat-format-limitations
Notice the file format is MS-DOS (FAT). MS-DOS? Really? Well, it’s at least an early, relatively primitive file format from the Windows side of things, though I can’t imagine a single person still running MS-DOS on their computer!

Got the right unit? Click on the “Erase” tab then pick “Mac OS Extended (Journaled)” — my recommendation for flash drive formats, though it does make it unreadable on a Windows PC — and enter a new name for the device if you’re so inspired:

windows-fat-format-limitations
Take another minute to quadruple check that you’ve picked the right device and click on “Erase…”

windows-fat-format-limitations
Absolutely sure you’ve picked the correct device? Click on “Erase” to proceed…

windows-fat-format-limitations
After a few moments, it shouldn’t take too long, your USB thumb drive will reappear on the Desktop with its new name and you can now drag that 5GB file onto the device for safekeeping. I’ll confirm by copying my own 4.93GB file:

windows-fat-format-limitations
That’s all there is to it. If you want to retain Windows compatibility with the flash drive, you might need to format it on a Windows PC using the NTFS (Windows NT File System) format. For reasons that are a bit hard to fathom, that’s not an option in Disk Utility on the Mac.

99 thoughts on “File too big error copying to USB flash drive on my Mac?”

  1. I have successfully saved a project from imovie on my desktop, as well as converted it with “Burn”. It is now prepared to export onto some sort of portable device. The file info says that the file is “8.27 GB”. I am trying to copy the file to a USB. With your tutorial help, I am aware of the formatting of the USB, etc., and have read that there is a limit of 4GB file size for transferring data to a USB with FAT32 formatting. I also see that I can transfer bigger files if I were to use the EXFAT[which I understand can be read by a MAC or a Windows] or the MAC OS Extended[which I understand can only be read on a MAC], etc options, BUT these solutions do not guarantee that the information will be able to be used with older equipment, etc. I really need a solution that can have the files transferred to AND that can be used by almost any operating system.

    Help? Thanks, in advance, for your time and expertise!!

    Reply
  2. thank you so much i also have the same problem before transferring large files…noe i can transfer it easily by formatting it by Mac OS Extended (journaled)…thanks

    Reply
  3. Thank you SO much! I had to transfer a large video file last-minute, and I was getting the same error. I was lucky enough to stumble upon your website, and, fortunately, was able to transfer my video file over to my flash drive.

    Once again, thank you so much for the help!

    Reply
  4. I’ve been having this problem with 2 USB drives, is it possible that the file is to blame? Also, my computer runs windows so is there an alternative way of doing this on windows?

    Reply
  5. Thanks ever so much. I had a 32gb flash, and 28gb file that wouldn’t go on, I almost tore out my hair but I’d had a haircut already. It is a very important file that needs sending asap so really, God bless you for sharing.

    Reply
  6. Ok I need to make sure I understand this.
    I already have 87gigs on the 500g external hard drive I am saving to.
    By doing this, will EVERYTHING be deleted from my drive? Or is it just reformatting so I can move the ms-dos files?

    Reply
  7. Thank you so much Dave. This was much faster and easier than I thought it would be, such a simple solution and it worked fantastic!

    Reply
  8. Thanks for the information however, my thumb drive comes back with an error – Couldn’t unmount disk. Can you please give me another idea or option.

    Reply
  9. So, catching up on this conversation as the instructions were fabulously clear – only one thing is missing in my brain to understand the whole process.
    What do I do if I´m on Mac but my client is on PC? Do I format to exFAT? Does the USB stick then work on both Mac and PC?

    I find it ridiculous that this is an issue this day and age!
    Thanks,
    Mi

    Reply
  10. I’m doing this so i can copy the file to a PC and you say that doing this will make it unreadable on PCs… so what do i do?

    Reply
  11. Maybe you don’t have to reformat the flash drive, which I would avoid. You could go to trusty Softpedia.com and get HJSplit for Java (it’s freeware) at:
    http://mac.softpedia.com/get/Utilities/HJSplit-for-Java.shtml
    (I’m not too fond of Java but…) Anyway, you can split the file into one piece of maybe 3.95GB, and another smaller one. Only drawback is you presumably won’t be able to open the file until you put it back together (on any platform).

    Reply
  12. Thanks for that note, Ken. I did more research and apparently there is support for NTFS within Mac OS X but it’s not stable and since it’s flaky Apple opted not to make it available for the general consumer. If you dig around on Facebook people have figured out some sneaky ways to enable it, though. Which still doesn’t mean you can use Disk Utility to reformat a thumb drive to work with NTFS, however. 🙂

    Reply
  13. [formatting NTFS] For reasons that are a bit hard to fathom, that’s not an option in Disk Utility on the Mac.
    I don’t have a Mac, so I can’t verify this, but…
    In helping a client move many gigs of files from his Windows box to his new Mac, he purchased an external USB drive. It was formatted NTFS, and included both Windows and Mac backup utilities. The manual included instructions for reformatted it for Mac OS (including the note to copy the Mac software off of it first), noting that, while the Mac could *read* NTFS, it couldn’t *write* to it.

    Reply

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