While using the Windows 7 USB/DVD Download Tool to create a bootable USB drive to use for reinstalling/repairing Windows, I ran into the following error message:
Windows 7 USB/DVD Download Tool error: We were unable to copy your files. Please check your USB device and the selected ISO and try again.
I found the following link to a discussion about the issue:
Then enter the following commands to identify and format the USB drive in question:
Microsoft DiskPart version 6.2.9200 Copyright (C) 1999-2012 Microsoft Corporation. On computer: KJONES-WIN8 DISKPART> list disk Disk ### Status Size Free Dyn Gpt -------- ------------- ------- ------- --- --- Disk 0 Online 931 GB 0 B * Disk 1 Online 29 GB 0 B Disk 2 Online 980 MB 0 B DISKPART> select disk 1 Disk 1 is now the selected disk. DISKPART> clean DiskPart succeeded in cleaning the disk. DISKPART> create partition primary DiskPart succeeded in creating the specified partition. DISKPART> select partition 1 Partition 1 is now the selected partition. DISKPART> active DiskPart marked the current partition as active. DISKPART> format quick fs=fat32 100 percent completed DiskPart successfully formatted the volume. DISKPART> assign DiskPart successfully assigned the drive letter or mount point. DISKPART>
After completing these steps to format the target USB drive, I was able to use the Windows 7 USB/DVD Download Tool to successfully create a bootable USB drive. Also note that despite the name, this tool also works to create bootable Windows 8 USB drives.
Further information about diskpart: