Last year I had to FTP into the CRIO and manually delete files to get it to come back. This was an old 8 slot CRIO. Technically I think MAX should be able to do the same thing through the GUI with a format, but I couldn't get it to work. Search NI for details on reformatting such as the one below:
http://digital.ni.com/public.nsf/all...256EE5007198D4