I saw the unallocated partition in disk management but could not expand the partition. Downloaded a free partition program and did the job.Check disk management to see if there is another partition on the drive. If not, its probably one of those fake drives.
I think when you create a boot USB, the program (either MS Windows Installer, or Macrium Reflect), it automatically formats it to FAT32.Sounds like it was formatted with FAT32, which has a 32GB limit.
Depends on BIOS and similar. Most utilities you use outside of Microsoft use a linux or open source derivative for file system.Can you boot from exFat or NTFS?