Fixed
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(I'm too impatient to wait for Garmin support to come back to me
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)
The problem was the corrupt GARMIN directory on the unit apparently.
If anyone has the same problem, then have a look at
this thread on the Garmin website, in particular post #32. Importantly it contains a link to a zip file of the garmin base map which you need after formatting the drive.
Note: importantly, to force Garmin to go into sync mode (at the very least so you can see the F: directory on the unit), then you need to hold down Mode and UP on the unit and and then plug into the computer. This is actually quite difficult and often I found it would go into hard reset mode (which is by pressing mode and start/plug into computer). The way I did it was to have the lead already plugged into the laptop but not in the unit. Then hold down mode, plug the cable into the unit, then as quick as you can press and hold UP (whilst still holding mode) until you see the little computer screen.
If anyone needs any help and comes across this thread, send me a message and i'll try and help.
I'd suggest if you own a Garmin device to have a backup copy of the main files on the unit (making sure to copy the directory names and their particular order too) and to back up history files at regular intervals. Luckily I only lost 2 days worth (40 miles) of data.