Hi Peter,
This issue needs to treated carefully because the B2 software and Operating System share the same storage device as the music This makes the recovery process more delicate as it would be very easy to delete your whole music collection by accident.
I'm assuming that you do not have a recent full Export backup.
The basic problem is that in order to revive your 64GB SD card, the card has to be reformatted and that will delete the existing music collection. So your music collection needs to be backed up to another location that is not on the B2.
First, can you Export (back up) the music from the old 66GB card to a PC or Mac? You will need a 'USB to SD card adapter'. If you don't have sufficient space on a PC/Mac, then you should also buy a 64GB USB stick.
Important note: Do not purchase USB sticks or memory cards from Amazon or eBay as many of these devices are fake and you will probably lose your collection. Buy these devices from reputable retailers such as Curry's or Argos in the UK or Best Buy in the USA.
To recover and rebuild your B2 and music collection here is the process.
1. Using a PC/Mac and a 'USB to SD card adapter' copy the contents of the 'music' directory from the B2's 64GB SD card to a safe location and verify that the music content is complete.
2. Power the B2 down if not already done.
3. Plug the new16GB SD card into the side of the B2
4. Remove the USB adapter and SD card from the PC and plug it into the B2's USC C port.
5. Go to 'Settings' --> 'Maintenance' -- 'Advanced' --> 'SD card to C' (this will copy the B2 software areas from the 16GB card on to the 64GB card).
6. Press and hold the 'Play/Stop' button until 'Saving' is displayed.
7. Power the B2 down.
8. Remove the USB adapter from the USB C port
9. Swap the 16GB card for the 64GB card, so that the 64GB card is now the B2 boot device.
10. Power up the B2 and check that is is functioning correctly and that it reports 62GB capacity (approximately) with 0GB used.
At this point you B2 is up and running, but with no music loaded.
11. Run 'Settings' --> 'Web Upgrade'
12. Plug the USB stick into the B2 and run 'Settings' --> 'Maintenance' --> 'Format USB C'
13. Remove the USB stick from the B2 and plug it into the PC
12. On the USB stick, 'create a folder named 'music' and copy all of the artist folders into this folder.
13. Plug this USB stick into the USB C port on the B2.
14. Select 'USB Functions' --> 'Import from C'
15. The Import will probably run for about 2 hours depending on how much music has to be loaded.
That should be it.
At step 5, if the there are any errors reported, it could mean that the 64GB card is permanently damaged, but in my experience it will probably OK. But you might need to purchase a new 64GB card.
Let us know how you get on.
Regards,
Peter.