The USB Key Utility for Windows only lists removable drives with a capacity of less than 33,000 MB by default.

However, in 2025, it’s quite difficult to find a USB drive that small.

You can follow the steps below to remove this unnecessary limitation:

1. Download the latest USB Key Utility for Windows v3.0.0.0 from HPE. You don’t need to log in to your account to get it.
2. Prepare a hex editor (I’ll use 010 Editor as an example below — this is not an ad).
3. Open usbkey.exe in the hex editor, press Ctrl+G and navigate to offset 0x6D56. Starting from that position, the next 2 bytes should be 77 35.
4. Replace both bytes with 90 90, then save the file.

>usbkey.exe
0000000000007956:77->90
0000000000007957:35->90

After completing these steps, the process isn’t finished yet.

Open Disk Management (diskmgmt.msc), delete all partitions on the USB drive, create a new partition smaller than 32 GB (I only tested with 30000 MB), format it, and assign a drive letter.

The USB drive’s partition style must be MBR; using GPT will prevent it from booting.