I've got the exact same problem - 4gig card, with well over 3gig spare, and it won't allow a save because, apparently, there isn't a spare 128k. Nice.
I've been searching the forums to find an answer, and I'm sure there is one. Various answers I've heard so far are:
a) Nothing to do with memory card, it's down to the internal memory of the unit being full. Which sounds plausible, until you mention that it's the very first game I ever tried on the machine. So nothing could have gone into the cache.
b) 'Faulty' cards. Maybe a few years ago, when portable flash memory was in its infancy and very hit & miss in quality. But this is a Sandisk and I've been using their various memory products for years now with no problems. Plus it's not faulty for any other function (saving other games, plugged into a PC via a card reader, playing mp3s on the PSP).
c) Lego Star Wars II won't allow a 'virgin' save onto large capacity cards. This sounds most likely to me. I think there might be a workaround whereby one can 'import' a save from another (working, lower capacity) memory card. Which means either buying another card (how much is 512meg nowadays?) or getting a save file from someone else.
Anyhow, still working on finding a fix. Will let you know if I get anywhere.
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