I have a ticket open, but figured I would see if anyone else experienced this problem. I have 2 Aio-5, 1 for BMW, and 1 non-BMW mounted on a KTM 790. Here's the problem:

1)  Check for updates and try to apply. Fails after about 6-7%. After some googling, that led me to making sure the SD Card was detected and formatted. 

2)  SD Card show Format Required. OK, lets format. No dice. Get a spinning circle forever, and never completes the format. Keep in mind it doesn't ever show Not Detected. Only that format is required. 

3)  Buy a new card (128gb Sandisk U3/A2/V30). Pop it in, same thing. 

Take both cards, and pop them in my Aio-5 BMW device, and voila. They both show the size, and they both formatted in a matter of seconds. 

Take both cards and pop them 1 at a time back in the KTM device, and again, no dice. Format Required. 

At this point I'm inclined to believe the card reader on that device isn't working correctly. I bought it 7 months ago, and I had issues trying to update back then as well. But I thought it might be my connection or operator error, and didn't come back to really look at it until now. 

Anyone else seen this and/or have a solution other than requesting a replacement? 

TIA.