If anybody still cares: :-)
Well, after many different experiments, what I am finding is that even though the Reader manual mentions specifically the 4GB Memory Stick, which would indicate to me that it can handle that size stick (especially since it also only specifically mentions a 2GB SD card) in reality at least for my reader, it can only handle 2GB of stored data, whether books or audio.
Using the Connect software, my 4GB card shows up as being 3.8GB (I expect that for formatting uses up some of the storage space) and the moment I try to put anything which moves the card below 1.8GB available space, I get an error message which states that the device is no longer available. If I remove some files so the level rises above 1.8GB available, the device becomes available for new data again.
If I use Windows Explorer and simply copy the files to get beyond that limit, the files don't all show up. This happens whether or not I have books stored on the card along with the MP3 files, and it happens whether or not I have the mp3 files all in one folder or stored in smaller numbers in different folders.
This is the same action I found with the 4GB SD card I experimented with.
So as long as I remain at or under 2GB of data on the memory card, all my mp3 files work just fine.
So from my experiments, it is obvious that the limit isn't on the number of mp3 files but rather the limit is on the amount of storage space the Reader recognizes.
I looked in the cache.xml which the reader stores in the Reader/Database folder on the memory card and when I put more than 2GB of audio files on the stick there are a lot of entries which start out with "<corrupted" where the other entries start out with "<audio" and there is no evident reason for which files get that "corrupted" entry. At first I was afraid the files might be corrupted, so I deleted them and then found that other songs which had previously had legitimate entries in the cache file now had the corrupted entries.
It's all very curious, but as long as I keep the stored data at or below 2GB everything's fine. If anybody has gotten different results with a 4GB memory stick, I'd be delighted to know the brand/model of memory stick you're using. Mine is the SanDisk 4GB Memory Stick Pro.
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