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This sounds like a problem with the MicroSD card in the R4. Some brands have been known to be incompatible. Without knowing more information about the R4 and the SD card
A couple of years ago, I had three microSD cards fail, even reformatting failed. I believe it was a problem with the R4's at the time. Try reformatting the microSD card in a PC, download the latest kernel and load that on to the microSD card, if you can get it to format.
Failing that, buy a new SD card. SanDisk/Transcend and Kingston are the preferred and recommended types. Is this an R4 or R4-SDHC? Don't use an SDHC(4gb+) memory card in a R4, only in R4-SDHC.
Memory cards are cheap enough 1gb-2gb don't cost that much, if you have an R4-SDHC then try a 4gb
I take it it was working at some point or other, or is this a new card?