Warioware D.I.Y. problems

So I used to play this Warioware D.I.Y. a lot during 1.7.1. but I haven't touched it for a while. I came back to it at after updating to 1.8.5 but I'm having a problem.
Every time I start up the game it says loading... then it says "System File is Missing". I never had this problem before and all my other games work EXCEPT for Warioware D.I.Y..
I tried reformatting the SD card using Panasonic SD formatter and redownload AKAIO 1.8.5. but I'm getting the same problem. Anyone know what's wrong because
it's awkward that this is the only game that doesn't work. (It is a good dump btw)

 

Hm using the Panasonic SD formatter it always set the cluster size to 32768 bytes and seems to be no way to change it. Do you recommend that I try another program to format?

 

I just tried 64kb cluster size using the windows formatter and I'm still having the same problem. (BTW I tried both 1.8.5 and 1.8.5a and the newest loader dated today? 2/13/2011)

 

The color of the text is green which according to you mean I need a larger cluster size. Windows only allows up to 64kb which I tried already. Any suggestions?

 

Well as I said on my previous posts I already used Panasonic SD formatter and I tried both 1.8.5 and 1.8.5.a
I don't have another micro SD card to try it out so I went back to version 1.8.1 and the game works fine.

Problem is now since I'm back to an older version some of the newer games I have don't work.
Normmatt do you have any idea what's the problem when I'm on 1.8.5? The "System File is Missing" text
is green but using a 64kb cluster size still gives me the same problem.