Try dd'ing the usb, and recreating the partition table with Gparted
plug in USB and open a root terminal
Code:
dd if=/dev/zero of=/dev/sdb bs=512 count=1
make sure you dont dd your hd!
the above will wipe the usb completely
make sure usb is sdb
after dd'ing it
remove usb, wait ten sec
reinsert usb and open gparted
you can open gparted on the usb from root terminal
then right-click on usb line and select
"new" and it will say it needs to make a msdos table
do that
then format and set boot flag of usb
thats how I fix my usb(s) when something really goes bad