Hi Oreo,
I have a Zaurus SL5500 SR3.10 just like yours. I also had problems at certain points with my backups failing. The thing is... The backup creates itself on the internal Zaurus RAM first, and once the backup is created it writes it out onto the CF or SD card. I have about 15-16 Mb of apps/games/etc installed into my Zaurus ram at the moment and there is about the same amount of free RAM available. I install as many apps/games onto SD card (fdisk-ed and made into an ext2 filesystem) as possible to free up as much Zaurus RAM. Even so, I have little spare space. Anyway, the backup works. If I install much more, I will probably end up with too large a backup file that overfills the tmp space and dies part-way.
Hope that helps....
1) Format sd card with ext2 file-system
2) Install apps to sd card if possible (fortunately lots of apps will install and run fine from sd)
3) Try not to exceed 15Mb of apps installed to internal Sharp RAM
4) Check available space with the System Info program in the Settings menu
5) Finally, if you still have problems with the backup, make sure there is space left on the sd card!! (Doh!)
Regards,
edo.