It doesn't work on my 1GB USB stick either, though i don't see the
traceback, just:

new device:
{'uuid': '', 'label': 'U3_System', 'free': 0, 'fstype': 'iso9660', 'device': 
'/dev/scd2', 'mountpoint': '', 'udi': 
'/org/freedesktop/Hal/devices/volume_label_U3_System_0'}
new device:
{'uuid': '', 'label': 'U3_System', 'free': 0, 'fstype': 'iso9660', 'device': 
'/dev/scd1', 'mountpoint': '', 'udi': 
'/org/freedesktop/Hal/devices/volume_label_U3_System'}
new device:
{'uuid': '', 'label': '', 'free': 0, 'fstype': '', 'device': '/dev/sdb1', 
'mountpoint': '', 'udi': 
'/org/freedesktop/Hal/devices/volume_part1_size_1020380672'}
mounting /home/mdz/iso/intrepid-desktop-i386.iso
target (0) is too small for source (729288704).
target (0) is too small for source (729288704).
target (0) is too small for source (729288704).
Installing...
installing the bootloader to /dev/sdb1.
Error installing the bootloader (syslinux -s /dev/sdb1)
mounting
copying from ISO...
['cp', '-ra', '/tmp/tmpcdzqro/.', '']
error_code 256
All done.


 I added some debugging as follows:

                        print 'target (%d) is too small for source (%d).' % (
                            val['free'], s_val['size'])

and it shows:

target (0) is too small for source (729288704).

it looks like this check isn't actually implemented yet.

** Changed in: usb-creator (Ubuntu)
   Importance: Undecided => Medium
       Status: New => Triaged

-- 
fails on 1GB usb stick
https://bugs.launchpad.net/bugs/264464
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