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I need to make a USB bootable disk of Windows 7 ISO.

My USB is formatted to NTFS, ISO is not corrupt. I can copy install.wim elsewhere but I cannot copy it to USB. I even tried rsync.

rsync error

sources/install.wim
rsync: writefd_unbuffered failed to write 4 bytes to socket [sender]: Broken pipe (32)
rsync: write failed on "/media/52E866F5450158A4/sources/install.wim": Input/output error (5)
rsync error: error in file IO (code 11) at receiver.c(322) [receiver=3.0.8]

Stat for windows.vim

  File: `X15-65732 (2)/sources/install.wim'
  Size: 2188587580  Blocks: 4274600    IO Block: 4096   regular file
Device: 801h/2049d  Inode: 671984      Links: 1
Access: (0664/-rw-rw-r--)  Uid: ( 1000/    umur)   Gid: ( 1000/    umur)
Access: 2011-10-17 22:59:54.754619736 +0300
Modify: 2009-07-14 12:26:40.000000000 +0300
Change: 2011-10-17 22:55:47.327358410 +0300

fdisk -l

Disk /dev/sdd: 8103 MB, 8103395328 bytes
196 heads, 32 sectors/track, 2523 cylinders, total 15826944 sectors
Units = sectors of 1 * 512 = 512 bytes
Sector size (logical/physical): 512 bytes / 512 bytes
I/O size (minimum/optimal): 512 bytes / 512 bytes
Disk identifier: 0xc3072e18

   Device Boot      Start         End      Blocks   Id  System
/dev/sdd1   *          32    15826943     7913456    7  HPFS/NTFS/exFAT

hdparm -I

/dev/sdd:
SG_IO: bad/missing sense data, sb[]:  70 00 05 00 00 00 00 0a 00 00 00 00 20 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00

ATA device, with non-removable media
    Model Number:       UF�F�A����U]r���U   u��tF�f�`~
    Serial Number:      �@󾽀~|
    Firmware Revision:  ����V�
    Media Serial Num:   $I�vnladip raititnot baelErrrol aoidgn
    Media Manufacturer: o eparitgns syetmiM
Standards:
    Used: unknown (minor revision code 0x0c75) 
    Supported: 12 8 6 
    Likely used: 12
Configuration:
    Logical     max current
    cylinders   17218   0
    heads       0   0
    sectors/track   128 0
    --
    Logical/Physical Sector size:           512 bytes
    device size with M = 1024*1024:           0 MBytes
    device size with M = 1000*1000:           0 MBytes 
    cache/buffer size  = unknown
Capabilities:
    IORDY(may be)(cannot be disabled)
    Queue depth: 11
    Standby timer values: spec'd by Vendor
    R/W multiple sector transfer: Max = 0   Current = ?
    Recommended acoustic management value: 254, current value: 62
    DMA: not supported
    PIO: unknown
       *    reserved 69[0]
       *    reserved 69[1]
       *    reserved 69[3]
       *    reserved 69[4]
       *    reserved 69[7]
Security: 
    Master password revision code = 60253
    not supported
    not enabled
    not locked
    not frozen
    not expired: security count
    not supported: enhanced erase
    71112min for SECURITY ERASE UNIT. 172min for ENHANCED SECURITY ERASE UNIT.
Integrity word not set (found 0xaa55, expected 0x80a5)
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Have you got another USB device to try? –  techie007 Oct 17 '11 at 20:44
    
all the others are less than 4gb. yet, i've seen that many people had experienced this problem, so it should be irrelevant from the usb device; yet hdparm results are little confusing –  Umur Kontacı Oct 17 '11 at 20:46
    
According to what you've posted, the install.wim is 2.1GB (2188587580), so that should fit on a USB that's <4GB (but >2.1GB)? The hsparm info under "Model", "Media Serial" and such is pretty sketchy looking, hence why I suggest trying another USB device :) –  techie007 Oct 17 '11 at 20:49
    
all the flashdrives i have are 2 gb right now, except the one that i am using =( –  Umur Kontacı Oct 17 '11 at 20:53
    
possible duplicate of Creating a Windows XP installation flash drive in linux –  techie007 Oct 17 '11 at 21:11
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6 Answers

I had the same problem copying install.wim to USB flash drive (I tried several), so I changed the cluster size.

Right Click the drive, under USB, select Format, then change cluster size from 4096 (default) to 16 Kilobytes, and try to copy install.wim again.

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I just had this problem. I copied all other files seperately and left the install.wim until last. When I did this I walked away. It took about 5-10mins but copied successfully.

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This doesn't help the questioner, where the copy doesn't work. –  Chenmunka Feb 18 at 11:35
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This doesn't address the specifics, but when creating bootable USBs from ISOs I have never run into a manual copying process. I usually use something like unetbootn as described in Create bootable windows 7 usb drive have you tried something like this?

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Of course I did=) I do use unetbootin for creating bootable usbs for linux, but for windows, the process is a little bit complicated. You have to copy the files and write a MBR for your windows version yourself. –  Umur Kontacı Oct 17 '11 at 21:00
    
It says that unetbootin can also prepare bootable usb's for windows but in my case it failed and it throw me to the boot console. –  Umur Kontacı Oct 17 '11 at 21:06
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I've come across that problem myself while creating a bootable USB.

  • On my first try, the copying process just stopped/froze.

  • The second try, with Total Commander - same thing 99% and that's it.

  • Third try (success), just regular copy/paste from Win7 CD/DVD -> USB and the same story, but this time I just let it be.

That third try, the time remaining started increasing but after 5 min progress bar moved again and the copying process was completed successfully.

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If unetbootin doesn't work, as @Dennis suggested, try YUMI (similar to unetbootin/universal USB installer). I can give it a .iso of a windows installer and a thumb drive, and it works like a charm. If it can't, it usually gives informative error messages.

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What is the error message when you try simply copying the file? Can you copy other things to the flash drive or simply touch a file on it? It's possible that one of three things is happening here:

  1. Your flash drive's filesystem is in a bad state, and you can't read/write to it. In this case, a reformat may help you out.
  2. It's possible that, because the install.wim is so large, that your filesystem can't handle the size of the file. Again, a re-format with the appropriate block size may help you out.
  3. The flash drive itself is dead. If a re-format doesn't fix the drive, you're better off finding something else.

You should be able to pick up a cheap 4GB for as little as $4 USD, so it shouldn't be the end of the world if it is indeed dead.

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