We did not run into this issue when we upgraded from 20.6 to 1.3.1, but 
from looking at the upgrade docs, we did a few things to try and protect 
any index corruption, which looks like what you ran into.

1 - we stopped any apps from writing to the indexes when we started our 
upgrade
2 - we flushed the cluster before bringing it down
3 - we disabled shard allocation/replication before bringing the cluster 
down (just to make sure all nodes brought back the indexes that were on the 
same machines.)
4 - when we brought everything back up, we ran optimize on each index.  
This was noted as a task to do, because all of the indexes are in new 
formats in the newer releases, so, it was recommend to run the optimize 
which would recreate all of the indexes.  It was unclear whether older 
indexes would really work in upgraded cluster. we did not take the chance 
and took the time hit to run optimize.
5 - re-enabled shard/replication allocations
6 - cluster was working just fine

hope our steps help you try and redo the cluster upgrade.

On Tuesday, September 9, 2014 4:18:54 PM UTC-7, Wei wrote:
>
> Hi All, 
>
> I'm working on an ES upgrade from v0.20.5 to v1.2.1
> I tested in a 2 node cluster, 3 indices, ~4 million docs, 18G file sizes, 
> 20 shards, 1 replicas
> However, after bumping the version and reboot the cluster, I kept on 
> seeing some shards are damaged. The ES log said: 
> Caused by: org.apache.lucene.index.CorruptIndexException: did not read all 
> bytes from file: read 451 vs size 452 (resource: 
> BufferedChecksumIndexInput(MMapIndexInput(path="/18/index/_195c_i.del")))
>
> This badly blocked the version upgrade in my case. 
> Could you any one point me the reason of this issue? 
> Lots appreciate to your help!
>
>
> Wei
>

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