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I'm trying to use the Windows 7 USB/DVD Download Tool from the Microsoft Store to make my new 16 GB USB Flash drive bootable to install Windows. It worked the first time that I did this (for Windows 7 Pro 32-bit), but now it keeps failing at the end. (I'm trying to make it bootable with the Windows 7 Pro 64-bit installation DVD ISO.) I've tried to do this on two different computers (Windows XP Pro 32-bit & Windows 7 Pro 32-bit) with the same error:

Files copied successfully. However, we were unable to run bootsect to make the USB device bootable. If you need assistance with bootsect, please click the "Online Help" link above for more information.

Clicking the link just takes me to the Microsoft store homepage, and a search for bootsect from there yields no search results. I've tried to burn a DVD twice using Sonic RecordNow!, but even though it finishes without "errors," the disk is unreadable. :( Does anyone know why this keeps failing and how I may fix it?

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up vote 17 down vote accepted

It would seem that bootsect was failing because the device was already bootable.

This morning I decided to try using it to boot with the Windows 7 Professional 64-bit installer image loaded on it, despite the failure, just to see what would happen. Surprise-surprise, it worked. -_-

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I just had the exact same "surprise". However, if you follow Ahmed's answer below from the start, it should work as well and the error message isn't shown—I did it on my sister's computer. :) – agarie Jul 8 '14 at 23:54
So in the future you can just delete the old files from the USB and simply extract/copy the new files. – jiggunjer Dec 30 '15 at 5:18

Launch a command prompt with admin rights and run the diskpart tool:

list disk
select disk #
create partition primary
select partition 1
format quick fs=fat32

The “list disk” command will show you the connected drives and with “select disk”, you can choose your USB stick. Be careful to select the right drive or else your day won’t have a happy end. The crucial step here is the “clean” command. It overwrites the MBR and the partition table (thereby, deleting everything on the stick). My guess is that WUDT misses this step and only formats the flash drive. It appears my memory stick had some odd partitions (which is not uncommon). When I tried WUDT again with this prepared stick, the Open Source tool mastered its task without further murmur.

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Thanks Ahmed Ghoneim it help me making a pendrive bootable which was showing error at first. – Namshum Jul 2 '14 at 9:24
Once you have selected a disk you can run the "disk detail" command to help confirm that you have selected the correct disk. This command shows you the size, make and type of disk selected. – Andy Davies Dec 28 '14 at 14:41

I was trying to create Win7x64 bootable USB stick. Using WinXPx32 SP3, the tool failed for me as described. Luckily, I was able to get access to a Win7x64 machine instead, and there it worked just fine.

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Same with Windows 10... looks like it only works on Windows 7. – Dean Kuga Nov 27 '15 at 1:20

The following description is taken from the tool's online help:

When creating a bootable USB device, I am getting an error about bootsect

To make the USB device bootable, you need to run a tool named bootsect.exe. In some cases, this tool needs to be downloaded from your Microsoft Store account. This may happen if you're trying to create a 64-bit bootable USB device from a 32-bit version of Windows. To download bootsect:

  1. Login to your Microsoft Store account to view your purchase history

  2. Look for your Windows 7 purchase.

  3. Next to Windows 7, there is an "Additional download options" drop-down menu.

  4. In the drop-down menu, select "32-bit ISO."

  5. Right-click the link, and then save the bootsect.exe file to the location where you installed the Windows 7 USB/DVD Download Tool (e.g. %UserProfile%\AppData\Local\Apps\Windows 7 USB DVD Download Tool).

  6. Once the file has been saved, go back to the Windows 7 USB/DVD Download tool to create your bootable USB device.

You can also download bootsect from the following location (registration is required but it's free):

share|improve this answer Copy the bootsect.exe into the folder Windows 7 USB DVD Download Tool is installed on and it should work.

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Try to format (FAT32) your USB drive but not using quick option !

You can then check again (using explorer or chkdsk) to see if all sectors are readable. After formating (from Windows 7) the USB drive will have proper Windows 7 MBR and PBR.

Never had problems with Windows 7 USB/DVD Download Tool.

Help for bootsect.exe -

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protected by Community May 16 '14 at 13:42

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