An Update. Today I had a PQ with 262 caches in it. First load onto GPSr only showed 50 caches. Deleted the file from GPSr. Set caches to GPSr from GSAK. Showed only 150 caches. Again deleted file from GPSr. Created same PQ with GPX 1.0 format, copy it to GPSr, only 15 caches show. Went back to original PQ, downloaded to GPSr (GPX format 1.01), only showed 8 caches. (getting more frustrated...) One last try. Using GSAK, download to GPSr and WOW all 262 caches now show in GPSr. Every time the gpx file was the correct file size on the GPSr, so I don't know what is going on. Obviously a bug in the software. It never used to do this - always showed every cache in the PQ. Spose I will just have to download it 5-10 times till it works...
P.S. I tried exporting from GSAK I think 4 times - only the last time it worked properly...