Probably my final update on this thread, as my new 1Tb drive is now fitted.
Here's what I did.
1) Made sure I have the latest copy of the schedule BUT, this turns out (as posted elsewhere) not to have been necessary.It was restored automatically.
2) Remove the drive. It's a very easy dismantle and removal. One cross-head screwdriver is all that was required. The Disk is fitted into a single unit that also contains a fan, so take care to remove the fan connector from the main board before pulling the drive unit out.
3) Next is where I had the only problem. I put both old and new drives into a dual external USB caddy, but my laptop did not recognize the drives. I hoped to at least see drive letters but nope - nothing.
4) I installed the Seagate DiscWizard software, as it can easily clone a drive, but this software will not run unless it can identify a seagate or Maxtor drive in the system, and it would NOT detect my seagate drives via USB. So, unless I fitted them internally to a desktop machine I was unable to do any cloning. (I thought I had Acronis True Image here but I didn't!)
5) So, next I installed the new drive, untouched, into the Humax, and from here things got very good! Good old hummy identified the drive, told me I needed to format it and after a couple of button clicks off it went. For a 1Tb drive it competed in a couple of minutes, which surprised me.
6) After formatting, used the 'Back' button to return to the main media menu, checked the schedule and everything was there. No need to restore from my backup.
7) Plugged the old drive into a USB caddy and it was recognized, so I just set the media to USB, located the video files, and selected the top menu for copy, used opt+ and set it to copy back to the new drive. It's running now and will probably keep going for a couple of days, though I'm not really sure of this.
8) Connected via WebIf page and I was given the option to download all the WebIf software again. After letting it finish the download and resetting on the Humax, averything was again as before.
End result looking good. I hoped to do a fast disk clone, but this is working fine, provided we don't have any power failures while it runs!
I hope this helps people thinking about replacing their hard drive. I'm pretty sure that this method would also work for updating the drive from 500Gb to 1Tb.
All the best to those who provided valuable information and gave me the confidence to do this. I can now reformat the old drive and see if I can fix any remaining sector errors and keep it as a spare.
Alan.