If it used to work, try just renaming your sys.txt to sys.old, and rename your Primo/save folder.
Then when you restart it should be 'from factory'.
If it still fails to start its possible that there is a problem with the SDcard perhaps and maybe some of the files are corrupt or unreadable.
I'm sure DkN will be able to point you in the right direction as far as firmware is concerned.
gpsunderground forums are a good source of info on iGo Primo should you need to look more closely just at that.
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