Right here's the output with debug compiled in but I've found a work-around.

Although the pendrive is unformatted, for historical reasons the init script 
tries to mount /dev/sda1 before /dev/sda. If I remove this first mount 
attempt then everything works as expected. It appears that trying to mount 
the non-existent partition confuses usb-storage somehow. I don't need this 
old behaviour any more so I can drop it.

It would still be good if the cause could be pinned down, let me know if 
anything else would help.


Linux version 2.4.30 ([EMAIL PROTECTED]) (gcc version 2.96 20000731 (Red Hat 
Linux 7.3 
2.96-113)) #1 Tue Jun 14 15:37:46 BST 2005
BIOS-provided physical RAM map:
 BIOS-e820: 0000000000000000 - 00000000000a0000 (usable)
 BIOS-e820: 00000000000f0000 - 0000000000100000 (reserved)
 BIOS-e820: 0000000000100000 - 000000001ff00000 (usable)
 BIOS-e820: 00000000ffb00000 - 0000000100000000 (reserved)
511MB LOWMEM available.
On node 0 totalpages: 130816
zone(0): 4096 pages.
zone(1): 126720 pages.
zone(2): 0 pages.
Kernel command line: initrd=install.img reset=1 console=ttyS1,9600 
BOOT_IMAGE=vmlinuz auto
No local APIC present or hardware disabled
Initializing CPU#0
Detected 799.438 MHz processor.
Console: colour VGA+ 80x25
Calibrating delay loop... 1595.80 BogoMIPS
Memory: 513876k/523264k available (1236k kernel code, 9004k reserved, 507k 
data, 80k init, 0k highmem)
Dentry cache hash table entries: 65536 (order: 7, 524288 bytes)
Inode cache hash table entries: 32768 (order: 6, 262144 bytes)
Mount cache hash table entries: 512 (order: 0, 4096 bytes)
Buffer cache hash table entries: 32768 (order: 5, 131072 bytes)
Page-cache hash table entries: 131072 (order: 7, 524288 bytes)
CPU: L1 I cache: 16K, L1 D cache: 16K
CPU: L2 cache: 256K
CPU serial number disabled.
Intel machine check architecture supported.
Intel machine check reporting enabled on CPU#0.
CPU: Intel Pentium III (Coppermine) stepping 06
Enabling fast FPU save and restore... done.
Enabling unmasked SIMD FPU exception support... done.
Checking 'hlt' instruction... OK.
POSIX conformance testing by UNIFIX
mtrr: v1.40 (20010327) Richard Gooch ([EMAIL PROTECTED])
mtrr: detected mtrr type: Intel
PCI: PCI BIOS revision 2.10 entry at 0xfb150, last bus=1
PCI: Using configuration type 1
PCI: Probing PCI hardware
PCI: Probing PCI hardware (bus 00)
Transparent bridge - Intel Corp. 82801BA/CA/DB/EB PCI Bridge
PCI: Using IRQ router PIIX/ICH [8086/2440] at 00:1f.0
Linux NET4.0 for Linux 2.4
Based upon Swansea University Computer Society NET3.039
Initializing RT netlink socket
apm: BIOS version 1.2 Flags 0x07 (Driver version 1.16)
Starting kswapd
Journalled Block Device driver loaded
Detected PS/2 Mouse Port.
pty: 256 Unix98 ptys configured
Serial driver version 5.05c (2001-07-08) with MANY_PORTS SHARE_IRQ SERIAL_PCI 
enabled
ttyS00 at 0x03f8 (irq = 4) is a 16550A
ttyS01 at 0x02f8 (irq = 3) is a 16550A
FDC 0 is a post-1991 82077
RAMDISK driver initialized: 16 RAM disks of 32768K size 1024 blocksize
Uniform Multi-Platform E-IDE driver Revision: 7.00beta4-2.4
ide: Assuming 33MHz system bus speed for PIO modes; override with idebus=xx
ICH2: IDE controller at PCI slot 00:1f.1
ICH2: chipset revision 5
ICH2: not 100% native mode: will probe irqs later
    ide0: BM-DMA at 0xf000-0xf007, BIOS settings: hda:DMA, hdb:pio
    ide1: BM-DMA at 0xf008-0xf00f, BIOS settings: hdc:pio, hdd:pio
hda: ST340015A, ATA DISK drive
blk: queue c02f13a0, I/O limit 4095Mb (mask 0xffffffff)
hdc: Hitachi XX.V.3.3.0.0, CFA DISK drive
ide0 at 0x1f0-0x1f7,0x3f6 on irq 14
ide1 at 0x170-0x177,0x376 on irq 15
hda: attached ide-disk driver.
hda: host protected area => 1
hda: 78165360 sectors (40021 MB) w/2048KiB Cache, CHS=4865/255/63, UDMA(100)
hdc: attached ide-disk driver.
hdc: 250368 sectors (128 MB) w/1KiB Cache, CHS=978/8/32
Partition check:
 hda: hda1 hda2 < hda5 hda6 hda7 hda8 > hda3
 hdc: hdc1
usb.c: registered new driver usbdevfs
usb.c: registered new driver hub
Initializing Cryptographic API
NET4: Linux TCP/IP 1.0 for NET4.0
IP Protocols: ICMP, UDP, TCP, IGMP
IP: routing cache hash table of 4096 buckets, 32Kbytes
TCP: Hash tables configured (established 32768 bind 65536)
NET4: Unix domain sockets 1.0/SMP for Linux NET4.0.
RAMDISK: Compressed image found at block 0
Freeing initrd memory: 1314k freed
VFS: Mounted root (ext2 filesystem).
init started:  BusyBox v0.60.5 (2005.06.14-12:52+0000) multi-call binary
SCSI subsystem driver Revision: 1.00
Initializing USB Mass Storage driver...
usb.c: registered new driver usb-storage
USB Mass Storage support registered.
usb-uhci.c: $Revision: 1.1.1.1 $ time 10:49:33 May 31 2005
usb-uhci.c: High bandwidth mode enabled
PCI: Found IRQ 11 for device 00:1f.2
PCI: Sharing IRQ 11 with 01:0d.0
usb-uhci.c: USB UHCI at I/O 0xd000, IRQ 11
usb-uhci.c: Detected 2 ports
usb.c: new USB bus registered, assigned bus number 1
Product: USB UHCI Root Hub
SerialNumber: d000
hub.c: USB hub found
hub.c: 2 ports detected
PCI: Found IRQ 7 for device 00:1f.4
usb-uhci.c: USB UHCI at I/O 0xd800, IRQ 7
usb-uhci.c: Detected 2 ports
usb.c: new USB bus registered, assigned bus number 2
Product: USB UHCI Root Hub
SerialNumber: d800
hub.c: USB hub found
hub.c: 2 ports detected
usb-uhci.c: v1.275:USB Universal Host Controller Interface driver
mount: Mounting /dev/sda1 on /mnt/usb failed: No such device or address
mount: Mounting /dev/sda on /mnt/usb failed: No such device or address
hub.c: new USB device 00:1f.2-1, assigned address 2
Manufacturer:         
Product: USB DISK Pro    
SerialNumber: 0746113B0033
scsi0 : SCSI emulation for USB Mass Storage devices
  Vendor:           Model: USB DISK Pro      Rev: 1.21
  Type:   Direct-Access                      ANSI SCSI revision: 02
Attached scsi removable disk sda at scsi0, channel 0, id 0, lun 0
SCSI device sda: 250880 512-byte hdwr sectors (128 MB)
sda: Write Protect is off
 sda:<7>usb-storage: queuecommand() called
 sda1 sda2 sda3 sda4
 I/O error: dev 08:01, sector 0
FAT: unable to read boot sector
mount: Mounting /dev/sda1 on /mnt/usb f I/O error: dev 08:00, sector 0
ailed: Invalid aFAT: unable to read boot sector
rgument
mount: Mounting /dev/sda on /mnt/usb failed: Invalid argument
 I/O error: dev 08:01, sector 0
FAT: unable to read boot sector
mount: Mounting /dev/sda1 on /mnt/usb f I/O error: dev 08:00, sector 0
ailed: Invalid aFAT: unable to read boot sector
rgument
mount: Mounting /dev/sda on /mnt/usb failed: Invalid argument
 I/O error: dev 08:01, sector 0
FAT: unable to read boot sector
mount: Mounting /dev/sda1 on /mnt/usb f I/O error: dev 08:00, sector 0
ailed: Invalid aFAT: unable to read boot sector
rgument
mount: Mounting /dev/sda on /mnt/usb failed: Invalid argument
 I/O error: dev 08:01, sector 0
FAT: unable to read boot sector
mount: Mounting /dev/sda1 on /mnt/usb f I/O error: dev 08:00, sector 0
ailed: Invalid aFAT: unable to read boot sector
rgument
mount: Mounting /dev/sda on /mnt/usb failed: Invalid argument

Please press Enter to activate this console. 


BusyBox v0.60.5 (2005.06.14-12:52+0000) Built-in shell (ash)
Enter 'help' for a list of built-in commands.

sh: can't access tty; job control turned off
/ # dmesg
ad boot sector
usb-storage: queuecommand() called
usb-storage: *** thread awakened.
usb-storage: Command TEST_UNIT_READY (6 bytes)
usb-storage: 00 00 00 00 00 00 c4 df 00 ec c4 df
usb-storage: Bulk command S 0x43425355 T 0x1e Trg 0 LUN 0 L 0 F 0 CL 6
usb-storage: Bulk command transfer result=0
usb-storage: Attempting to get CSW...
usb-storage: Bulk status result = 0
usb-storage: Bulk status Sig 0x53425355 T 0x1e R 0 Stat 0x0
usb-storage: scsi cmd done, result=0x0
usb-storage: *** thread sleeping.
usb-storage: queuecommand() called
usb-storage: *** thread awakened.
usb-storage: Command TEST_UNIT_READY (6 bytes)
usb-storage: 00 00 00 00 00 00 00 00 00 00 00 00
usb-storage: Bulk command S 0x43425355 T 0x1f Trg 0 LUN 0 L 0 F 0 CL 6
usb-storage: Bulk command transfer result=0
usb-storage: Attempting to get CSW...
usb-storage: Bulk status result = 0
usb-storage: Bulk status Sig 0x53425355 T 0x1f R 0 Stat 0x0
usb-storage: scsi cmd done, result=0x0
usb-storage: *** thread sleeping.
usb-storage: queuecommand() called
usb-storage: *** thread awakened.
usb-storage: Command READ_6 (6 bytes)
usb-storage: 08 00 00 00 01 00 00 00 00 00 00 00
usb-storage: Bulk command S 0x43425355 T 0x20 Trg 0 LUN 0 L 512 F 128 CL 6
usb-storage: Bulk command transfer result=0
usb-storage: usb_stor_transfer_partial(): xfer 512 bytes
usb-storage: usb_stor_bulk_msg() returned -32 xferred 0/512
usb-storage: clearing endpoint halt for pipe 0xc0008280
usb-storage: usb_stor_clear_halt: result=0
usb-storage: usb_stor_transfer_partial(): unknown error
usb-storage: Bulk data transfer result 0x2
usb-storage: Attempting to get CSW...
usb-storage: Bulk status result = 0
usb-storage: Bulk status Sig 0x53425355 T 0x20 R 512 Stat 0x1
usb-storage: -- transport indicates command failure
usb-storage: Issuing auto-REQUEST_SENSE
usb-storage: Bulk command S 0x43425355 T 0x21 Trg 0 LUN 0 L 18 F 128 CL 6
usb-storage: Bulk command transfer result=0
usb-storage: usb_stor_transfer_partial(): xfer 18 bytes
usb-storage: usb_stor_bulk_msg() returned 0 xferred 18/18
usb-storage: usb_stor_transfer_partial(): transfer complete
usb-storage: Bulk data transfer result 0x0
usb-storage: Attempting to get CSW...
usb-storage: Bulk status result = 0
usb-storage: Bulk status Sig 0x53425355 T 0x21 R 0 Stat 0x0
usb-storage: -- Result from auto-sense is 0
usb-storage: -- code: 0x70, key: 0x5, ASC: 0x20, ASCQ: 0x0
usb-storage: Illegal Request: invalid command operation code
usb-storage: scsi cmd done, result=0x2
usb-storage: *** thread sleeping.
 I/O error: dev 08:00, sector 0
FAT: unable to read boot sector
usb-storage: queuecommand() called
usb-storage: *** thread awakened.
usb-storage: Command TEST_UNIT_READY (6 bytes)
usb-storage: 00 00 00 00 00 00 00 00 60 cb 2c c0
usb-storage: Bulk command S 0x43425355 T 0x22 Trg 0 LUN 0 L 0 F 0 CL 6
usb-storage: Bulk command transfer result=0
usb-storage: Attempting to get CSW...
usb-storage: Bulk status result = 0
usb-storage: Bulk status Sig 0x53425355 T 0x22 R 0 Stat 0x0
usb-storage: scsi cmd done, result=0x0
usb-storage: *** thread sleeping.
usb-storage: queuecommand() called
usb-storage: *** thread awakened.
usb-storage: Command TEST_UNIT_READY (6 bytes)
usb-storage: 00 00 00 00 00 00 00 00 00 00 00 00
usb-storage: Bulk command S 0x43425355 T 0x23 Trg 0 LUN 0 L 0 F 0 CL 6
usb-storage: Bulk command transfer result=0
usb-storage: Attempting to get CSW...
usb-storage: Bulk status result = 0
usb-storage: Bulk status Sig 0x53425355 T 0x23 R 0 Stat 0x0
usb-storage: scsi cmd done, result=0x0
usb-storage: *** thread sleeping.
usb-storage: queuecommand() called
usb-storage: *** thread awakened.
usb-storage: Command READ_6 (6 bytes)
usb-storage: 08 14 fd 29 01 00 00 00 00 00 00 00
usb-storage: Bulk command S 0x43425355 T 0x24 Trg 0 LUN 0 L 512 F 128 CL 6
usb-storage: Bulk command transfer result=0
usb-storage: usb_stor_transfer_partial(): xfer 512 bytes
usb-storage: usb_stor_bulk_msg() returned -32 xferred 0/512
usb-storage: clearing endpoint halt for pipe 0xc0008280
usb-storage: usb_stor_clear_halt: result=0
usb-storage: usb_stor_transfer_partial(): unknown error
usb-storage: Bulk data transfer result 0x2
usb-storage: Attempting to get CSW...
usb-storage: Bulk status result = 0
usb-storage: Bulk status Sig 0x53425355 T 0x24 R 512 Stat 0x1
usb-storage: -- transport indicates command failure
usb-storage: Issuing auto-REQUEST_SENSE
usb-storage: Bulk command S 0x43425355 T 0x25 Trg 0 LUN 0 L 18 F 128 CL 6
usb-storage: Bulk command transfer result=0
usb-storage: usb_stor_transfer_partial(): xfer 18 bytes
usb-storage: usb_stor_bulk_msg() returned 0 xferred 18/18
usb-storage: usb_stor_transfer_partial(): transfer complete
usb-storage: Bulk data transfer result 0x0
usb-storage: Attempting to get CSW...
usb-storage: Bulk status result = 0
usb-storage: Bulk status Sig 0x53425355 T 0x25 R 0 Stat 0x0
usb-storage: -- Result from auto-sense is 0
usb-storage: -- code: 0x70, key: 0x5, ASC: 0x20, ASCQ: 0x0
usb-storage: Illegal Request: invalid command operation code
usb-storage: scsi cmd done, result=0x2
usb-storage: *** thread sleeping.
 I/O error: dev 08:01, sector 0
FAT: unable to read boot sector
usb-storage: queuecommand() called
usb-storage: *** thread awakened.
usb-storage: Command TEST_UNIT_READY (6 bytes)
usb-storage: 00 00 00 00 00 00 c4 df 00 ec c4 df
usb-storage: Bulk command S 0x43425355 T 0x26 Trg 0 LUN 0 L 0 F 0 CL 6
usb-storage: Bulk command transfer result=0
usb-storage: Attempting to get CSW...
usb-storage: Bulk status result = 0
usb-storage: Bulk status Sig 0x53425355 T 0x26 R 0 Stat 0x0
usb-storage: scsi cmd done, result=0x0
usb-storage: *** thread sleeping.
usb-storage: queuecommand() called
usb-storage: *** thread awakened.
usb-storage: Command TEST_UNIT_READY (6 bytes)
usb-storage: 00 00 00 00 00 00 00 00 00 00 00 00
usb-storage: Bulk command S 0x43425355 T 0x27 Trg 0 LUN 0 L 0 F 0 CL 6
usb-storage: Bulk command transfer result=0
usb-storage: Attempting to get CSW...
usb-storage: Bulk status result = 0
usb-storage: Bulk status Sig 0x53425355 T 0x27 R 0 Stat 0x0
usb-storage: scsi cmd done, result=0x0
usb-storage: *** thread sleeping.
usb-storage: queuecommand() called
usb-storage: *** thread awakened.
usb-storage: Command READ_6 (6 bytes)
usb-storage: 08 00 00 00 01 00 00 00 00 00 00 00
usb-storage: Bulk command S 0x43425355 T 0x28 Trg 0 LUN 0 L 512 F 128 CL 6
usb-storage: Bulk command transfer result=0
usb-storage: usb_stor_transfer_partial(): xfer 512 bytes
usb-storage: usb_stor_bulk_msg() returned -32 xferred 0/512
usb-storage: clearing endpoint halt for pipe 0xc0008280
usb-storage: usb_stor_clear_halt: result=0
usb-storage: usb_stor_transfer_partial(): unknown error
usb-storage: Bulk data transfer result 0x2
usb-storage: Attempting to get CSW...
usb-storage: Bulk status result = 0
usb-storage: Bulk status Sig 0x53425355 T 0x28 R 512 Stat 0x1
usb-storage: -- transport indicates command failure
usb-storage: Issuing auto-REQUEST_SENSE
usb-storage: Bulk command S 0x43425355 T 0x29 Trg 0 LUN 0 L 18 F 128 CL 6
usb-storage: Bulk command transfer result=0
usb-storage: usb_stor_transfer_partial(): xfer 18 bytes
usb-storage: usb_stor_bulk_msg() returned 0 xferred 18/18
usb-storage: usb_stor_transfer_partial(): transfer complete
usb-storage: Bulk data transfer result 0x0
usb-storage: Attempting to get CSW...
usb-storage: Bulk status result = 0
usb-storage: Bulk status Sig 0x53425355 T 0x29 R 0 Stat 0x0
usb-storage: -- Result from auto-sense is 0
usb-storage: -- code: 0x70, key: 0x5, ASC: 0x20, ASCQ: 0x0
usb-storage: Illegal Request: invalid command operation code
usb-storage: scsi cmd done, result=0x2
usb-storage: *** thread sleeping.
 I/O error: dev 08:00, sector 0
FAT: unable to read boot sector


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