R32 HD upgrade to 120 GB USB problem

[R32]

I upgraded my 40GB HD to 120GB, copy the hidden partition using partition magic v8. After couple of trial and error able to install the Product Program Recovery but my USB cannot recognise the external HD and windows says that driver was not installed.
Only the HD is giving error thru the USB but other devices was working fine.

I got error also using Partiton Magic V8 with the new HD it gives message " Disk 1 (114470MB 15505c 240h 63s) appear to have partitions created using different drive geometry ( 255h 63s ). This serious problem can lead to data lost. No partition manipulation should made to this disk using this product or the operating system's products. You should back up the data on this disk, delete all partitions, create new partitions under the new drive geometry, and restore your data using the backup.
Addition error message was Init Failed: Error 117. Partition's drive letter cannot be identified

Can anyone advice me. Thanks in advance.