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While using the Windows 7 USB/DVD Download Tool to create a bootable USB drive to use for reinstalling/repairing Windows, I ran into the following error message:

Windows 7 USB/DVD Download Tool error: We were unable to copy your files.  Please check your USB device and the selected ISO and try again.

I found the following link to a discussion about the issue:

http://answers.microsoft.com/en-us/windows/forum/windows_7-windows_install/unable-to-copy-files-using-windows-7-usbdvd/bd21e76d-5174-4f76-8db5-36df105a12c5

Following the steps proposed by user @Siva2007 resolved the issue for me. Open a command prompt with administrator privileges and type:

diskpart

Then enter the following commands to identify and format the USB drive in question:

Microsoft DiskPart version 6.2.9200
Copyright (C) 1999-2012 Microsoft Corporation.
On computer: KJONES-WIN8
DISKPART> list disk
  Disk ###  Status         Size     Free     Dyn  Gpt

Using diskpart to Format a USB Drive in Windows

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