User Feedback :: Input/output error

I have some problems with my USB pendrive. (It is 1GB JetFlash.)

I have installed DSL on it (USB-ZIP) and everything works well.
But after few reboots I get this error when copying files from/to it.
And backup.tar file becomes corrupted too, so when restoring from this file on boot I get lots of I/o errors. Because of ext2 I could not acces this partition at Windows.

I fully reformated it and booted from CD. But again after backuping on sda1 I get this errors.
(For example: cp: reading `/mnt/sda1/mFormat.exe': Input/output error)

Tried with DSL 3.0 and 3.2 and N-DSL.

Maybe it is because of some *.unc or *.uci extensions?
I always had all my extensions on this drive. (at sda2 when DSL was installed on it and on sda1 after reformating and booting from CD). Loading them localy from drive.

USB-ZIP doesn't format to ext2. It formats to FAT16. I would try another USB drive first.

original here.