Install VMware ESXi 4.1 from bootable USB stick

Not all servers nowadays have a DVD player installed. Sometimes it is handy to boot from USB and installing a single VMware ESXi server. Here’s a example how to make the USB stick bootable and install VMware ESXi 4.1 from it by using Windows.

Preparation:

  • Need 1GB USB memory stick or more.
  • Download the VMware ESXi 4.1 ISO named VMware-VMvisor-Installer-4.1.0-260247.x86_64.iso (In this example I used the VMware vSphere Hypervisor version).

Update: The latest version of VMware ESXi is  4.1 Update 1 (VMware-VMvisor-Installer-4.1.0.update1-348481.x86_64.iso). It solves the “Total number of sectors” bug in VMware ESXi 4.1. It is recommend to use this version so the “mod.tgz” workaround isn’t needed anymore!

  • Download Syslinux, can be found by clicking on the following  link. Download the latest Syslinux zip file (when writing this article  syslinux-4.02.zip was the latest).

Update: Also tested Syslinux version 4.03.

Stick the USB stick on a  free USB port on your computer equipped with a Windows OS. For this example I used Windows7 as Operating System. Clear the USB stick and create a partition on it by using the following command’s:

  • Open the command prompt and enter the following commands:
Diskpart (make sure you run diskpart as administrator) 

list disk (list the disk in your system including the USB) 

select disk USB number 

clean 

create partition primary 

active 

format fs=fat32 quick 

assign 

exit

 

To make the USB stick bootable:

  • Extract the Syslinux ZIP and browse to the the \syslinux\win32 folder,  execute “syslinux [drive letter USB stick]”, example syslinux f:
  • Mount the ISO  and copy all the content of the VMware ESXi 4.1 ISO to the USB stick. For mounting the ISO, I used ‘Deamon Tools Lite’ tool.
  • Rename the isolinux.cfg file to syslinux.cfg
  • Edit the syslinux.cfg and add ks=usb and on the end of the append line — mod.tgz (beware of the space between and the mod.tgz).

Update: When using VMware ESXi 4.1 Update 1 the mod.tgz line doesn’t need to append!

default menu.c32

menu title VMware VMvisor Boot Menu

timeout 80

 

label ESXi Installer

menu label ^ESXi Installer

kernel mboot.c32

append vmkboot.gz ks=usb --- vmkernel.gz --- sys.vgz --- cim.vgz --- ienviron.vgz --- install.vgz --- mod.tgz

 

label ^Boot from local disk

menu label ^Boot from local disk

localboot 0x80

  • Create a ks.cfg file in the root from the UBS stick. For example:
rootpw VMware01

install usb

autopart --firstdisk --overwritevmfs

reboot

 

#Network install type

network --bootproto=static --addvmportgroup=false --device=vmnic0 --ip=192.168.1.10 --netmask=255.255.255.0 --gateway=192.168.1.1  --nameserver=192.168.1.1 --hostname=ESXi-01.beerens.local

accepteula

 

%firstboot --unsupported --interpreter=busybox

vim-cmd hostsvc/datastore/rename datastore1 "$(hostname -s)-local-storage-1"

  • Copy the syslinux-4.02\com32\mboot\mboot.c32 file the USB stick (overwrite the old file on the USB stick) 
  • Copy the syslinux-4.02\com32\menu\menu.c32 file the USB stick (overwrite the old file on the USB stick)

The bootable VMware ESXi 4.1 stick is ready for use. When booting  the USB stick the following message is displayed “Total number of sectors not a multiple of sectors per track! Add mtools_skip_check=1 to your .mtoolsrc file to skip this test”.

image

Update: When using VMware ESXi 4.1 Update 1 this bug is fixed. You’re ready to use the USB stick!

On the VMware communities I found the following post. This post states a manual solution by using the following commands:

  • Press ALT-F1
  • Login by using the root account with no password
  • echo “mtools_skip_check=1”>.\mtoolsrc
  • ALT+F2 and return to the orginal Console  window
  • Press ENTER or wait to continue

To automate the above solution read the following blogpost “VMware ESX 4.1 install using Western Digital USB Hard Drive” . By using  this blogpost I created a mod.tgz file by using the following commands from a full installation of VMware ESXi 4.1:

  • Login the VMware ESXi 4.1 console
  • Make a directory in the root for example mkdir temp
  • cd temp
  • mkdir –p etc/vmware/init/init.d/
  • cd etc/vmware/init/init.d/
  • vi 47.mtoolshack
echo "mtools_skip_check=1" >/.mtoolsrc

return ${SUCCESS}

  • Save the fi using the command :wq in VI
  • cd /temp
  • tar czvf mod.tgz etc
  • SCP the file mod.tgz file to the USB stick

The mod.tgz can also downloaded, so the above steps can be skiped. On the end of this article is a download link for the mod.tgz.

The mod.tgz contains an init script which skips the mtools check. Now you’re ready to boot your server with the USB stick and your able to install  VMware ESXi 4.1.                 

Download mod.tgz

Update : When using VMware ESXi 4.1 Update 1 there is no need to add the mod.tgz because this bug is fixed.

 

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58 thoughts on “Install VMware ESXi 4.1 from bootable USB stick”

  1. Thankyou so much. This worked like a charm.
    I have been trying to automate the creation of a USB drive to install ESXi 4.1. I need to use windows to format the USB drive and was getting the error “Total number of sectors not a multiple of sectors per track!”

  2. Thanks.

    I was stuck trying to install the new HP Proliant MicroServer from a USB key. I used UNetbootin to create the USB boot drive from the VMware ISO image, but with a simple KS script, I was stuck on the mtools error.

    With your mod.tgz file added to the append command, works like a charm.

  3. Why going through all these troubles while u could have ESXi does all the dirty work for you by using a VMware workstation. I did just that in 5 minutes, no download, no formatting and no brainer. I verified and ensured it did work by booting the USB drive on a HP DL380 G5. 🙂

  4. @MobyChien

    There is a difference between this blogpost and the VMware Workstation method.

    The method in this blogpost is about creating a bootable VMware ESXi 4.1 install USB media. It is possible to boot and install one or more server with VMware ESXi 4.1 to the local harddisk of the server(s) for example.

    The VMware Workstations method is only about creating a bootable USB VMware ESXi 4.1 stick.

  5. Thanks for pointing out the difference. I followed your instructions and got it working (almost), except:

    1. syslinux-4.02\com32\mboot\menu.c32
    should be “syslinux-4.02\com32\menu\menu.c32”
    2. The installer does not recognize the following command in ks.cfg:
    vim-cmd hostsvc/datastore/rename datastore1 “$(hostname -s)-local-storage-1”
    BTW, the latest syslinux is 4.03 now.

  6. I have followed all these instructions closely and find that I just get a different error everytime I try and run this. Either ks=usb can not be found, or the Total number of sectors not a multiple of sectors per track! Add mtools_skip_check=1 to your .mtoolsrc file to skip this test error even though I have downloaded and added the Mod file. has no one automated this process yet?

    Thank you

    Simon

  7. I am having trouble getting this to work. Do I need to extract the mod.tar file or just rename it to mod.tgz?

  8. I create new blocks for the code, so the copy/paste work better.

    @SimpleSimon Copy the code from the site and make sure the — mod.tgz is added to the syslinux.cfg. There is a space between — and mod.tgz

    @Richard No download the mod.tgz and copy the file to the root of the USB stick, make sure that the

  9. Installation works fine, i’ve copied mod.tgz to usb stick, but when i like to custumize my system it requires a password, …

  10. Hello,

    Use the latest official download of “ESXi 4.1 Installable”. Edit the syslinux.cfg and ks.cfg as exactly as shown above you can copy paste if you like however remove the — mod.tgz from the steps and use “syslinux 4.03” and remmember to have a ethernet cable attached and you are good to go without any of the errors previously stated on with versions 4.02 and 4.03.

  11. Perfect. It worked like a charm on HP ML110 G6. Couple of confusions from the blog at first point but later on were sorted out. May be hlepful for others reading this blog.

    I could not see USB stick in list after using DiskPart command. so i bypassed this process and it worked without any problem for me

    After pressing Alt F1, the command you enter, is shown wrong in this blog at the first stage but is corrected on command prompt screen print i.e. echo “mtools_skip_check=1” >/.mtoolsrc

    For new commers to VMWare like me, the defalut password for root has been changed to “VMware01” in ks.cfg file :). At first point i was confused why its not loging in with defalut blank password. he he he

  12. As per Richard’s post (below), the mod.tgz is downloading as mod.tar even though the hyperlink points to “https://www.ivobeerens.nl/wp-content/uploads/mod.tgz”. I downloaded it on both an XP and a Windows 7 machine with the same result. Any Ideas? The file inside the archive (mod.tar) is mod with no extension. Should I rename mod.tar to mod.tgz or extract mod and name it mod.tgz?

    Thanks,
    Colin

    QUOTE:
    “Richard:
    November 2, 2010 at 18:10
    I am having trouble getting this to work. Do I need to extract the mod.tar file or just rename it to mod.tgz?”

  13. Great article. The final mile to get it up on my Dell Studio 540 (after getting an intel gig. server network card).

    nothing seemed to happen when I did the “syslinux [drive]:”, so here’s my workaround:
    -Unetbootin to create the bootable usb from iso.
    -only appended “ks=usb” to syslinux.cfg,
    -created ks.cfg (changed network setting in file),
    -and during install did the ” echo “mtools_skip_check=1”>.\mtoolsrc ” tip.

  14. As some other replies have noted, I downloaded the mod.tgz, added it to the syslinux.cfg APPEND. Thanks for that. However, I don’t see the value of adding the kickstart usage in this post. I think most people will just be happy to have their flash drive run exactly as the esxi installer iso does; if so, they should leave out the ks=usb and not create the ks.cfg.

  15. I am not a linux wiz by any means so forgive my linux ignorance. What is the answer to this question?

    ” Colin:
    January 7, 2011 at 01:31
    As per Richard’s post (below), the mod.tgz is downloading as mod.tar even though the hyperlink points to “https://www.ivobeerens.nl/wp-content/uploads/mod.tgz”. I downloaded it on both an XP and a Windows 7 machine with the same result. Any Ideas? The file inside the archive (mod.tar) is mod with no extension. Should I rename mod.tar to mod.tgz or extract mod and name it mod.tgz?

    Thanks,
    Colin

    QUOTE:
    “Richard:
    November 2, 2010 at 18:10
    I am having trouble getting this to work. Do I need to extract the mod.tar file or just rename it to mod.tgz?”

    Thank you in advance for your help.

  16. Also, after i put in the mtools check skip line manually everything appears to install successfully and the system says it needs to reboot. After a reboot however, the esxi os is no there. What is going on?

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