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I had the same problem with 32gb microSD card.
It worked once on the Kobo H20 and then never again. I kept getting errors to reformat the card in FAT32. I formated it in Linux in FAT32 and still had problems. I formated it on winbloz7 in FAT32 and still had the problem. I partitioned the card into two 16gb patritions and still had the problem. I had another microSD card that was formated as FAT16 and I had no issues using that card.
In the end, I formated the card on Linux as FAT32 but then I decided to use cfdisk to set the partition type as FAT16, since my FAT16 card was working fine I figured I would try changing the file system type. I used type 04 = FAT16 <32m and 06 = FAT16. Either worked fine and presently I am using 04. When I tried EF = (EFI (FAT-12/16/32) it worked sometimes but I would usually get the kobo message that would say to reformat the card in FAT32.
So, for whatever reason, the kobo does better with FAT16 than a FAT32 file system, regardless of what they say.
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