Hi Donny,
Can you explain how the installation of expansion packs alter your keyboard setup? Did you make your own personal expansion pack through Yamaha Expansion Manager to include all your favorable sounds and styles and install them into the expansion flash area of your PSR-S970?
As far as I know, all the sounds, styles, registrations, multipads, etc. can be stored in your USB flash drive of your PSR-S970. Your keyboard setup should involve only the USB drive, not the expansion flash unless you have some previously purchased expansion packs that you use for your gigs. There should be no conflicts between using your USB drive and the 512MB expansion flash, which is dedicated to expansion pack installation and read-only after pack installation.
Thanks,
Paul
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Yamaha Genos, Ketron SD90, Korg Kronos 2 88, Korg PA1000, Casio Privia PX560