USB booting :: Total sectors not a multiple of sectors per track

I got an error like the bolded lines below when trying to install syslinux to my USB pen drive:

dsl@box:~$ sudo su
root@ttyp1[dsl]# ./syslinux -o bootusb-o.8.img /dev/sda1
Total number of sectors not a multiple of sectors per track!
Add mtools_skip_check=1 to your .mtoolsrc file to skip this test

I was unable to get the special parameter to work by adding it to the .mtoolsrc file. I don't know why. I put the file in the same directory as the syslinux command, but it didn't seem to make a difference. I continued to get the same error message. But simply exporting the parameter worked fine:

root@ttyp1[dsl]# export MTOOLS_SKIP_CHECK=1

After I did this, the syslinux command completed successfully:

root@ttyp1[dsl]# ./syslinux -o bootusb-o.8.img /dev/sda1
root@ttyp1[dsl]#

I haven't heard of anyone else having this problem, so I'm not sure how common it is. I have a Lexar 256M Jump Drive Pro. Note that the MTOOLS_SKIP_CHECK setting has to be exported in upper case. It doesn't work if it's in lower case.

I just thought I'd mention this in case anyone else encounters it.

I had this problem before.

The solution: back up your data. Then run "fdisk /dev/sda" (assuming sda is your flash drive. Don't do sda1; that's a partition). Delete (type "d") partition 1. Now add a new partition (type "n"), then when it asks you if you want a primary or extended partition, type 'p'. When it asks you for a partition number, type 1. Just <ENTER> through everything else. Now type 'a<ENTER>.' Finally, 't<ENTER>6<ENTER>'.

original here.