There many number of ways in which a bootable USB drive can be made using open source Linux distributions (Live CD .iso images) or Microsoft Windows XP/7. First thing to know is that inappropriate use of tools available for creating bootable disks can cause loss of data.
These tools work at the lowest level of disk structure, particularly the boot sectors. If you accidentally damage the partition structure of your disk(especially primary disk) then you should be prepared with the rescue tools mentioned in earlier post. You can make different bootable usb flash drives by following ways -
1. Linux Live CDs (Ubuntu/Mandriva/Fedora/Puppy Linux/Slitaz/Tiny core or any other)
You can make bootable USB drives using Universal USB installer (pendrivelinux.com) OR LinuxLive USB creator both which can a user friendly interface and guide you through step by step instructions. More than one Linux distribution can also be booted form the same flash drive (multiboot).
2. Windows XP or Windows 7 Live bootable CD and USB drive
Windows XP live bootable CD (called as BartPE) can be made from a disk containing the XP setup files using PEBuilder. There is an option to create an .iso image of BartPE. Then this iso image can be transferred to USB drive using pe2usb.
Windows 7 live bootable CD can be created using the WinBuilder tool. It has inbuilt functionality to create bootable USB flash drive. Most of the tools mentioned above should work even for a secondary Hard disk drive but the root drive of disk must be chosen to create boot disk.
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