Format it with your computer first. Most USB Flash Drives come with special formatting and security software for PC use. Re-Format the Flash drive on the PC to "purify" it and get rid of the special software, etc. After that let the KPA format it again. Then return to your PC and copy the upgrade files to the Flash Drive....then back to the KPA and perform the upgrade.
musicman, how do i format usb w/computer ? i would really like to get the update done this wk/end, thanks to all for you replies..roger