additional debug:
Insert SD 2Gb card:

# fdisk -l /dev/sda1

Disk /dev/sda1: 63 heads, 62 sectors, 1016 cylinders
Units = cylinders of 3906 * 512 bytes

     Device Boot    Start       End    Blocks   Id  System
/dev/sda1p1   ?    478641    930783 883032122   74  Unknown
Partition 1 has different physical/logical beginnings (non-Linux?):
     phys=(288, 115, 35) logical=(478640, 45, 32)
Partition 1 has different physical/logical endings:
     phys=(82, 111, 32) logical=(930782, 6, 41)
Partition 1 does not end on cylinder boundary:
     phys=(82, 111, 32) should be (82, 62, 62)
/dev/sda1p2   ?    465655    467357   3324218+  6f  Unknown
Partition 2 has different physical/logical beginnings (non-Linux?):
     phys=(66, 107, 32) logical=(465654, 15, 57)
Partition 2 has different physical/logical endings:
     phys=(288, 111, 52) logical=(467356, 22, 47)
Partition 2 does not end on cylinder boundary:
     phys=(288, 111, 52) should be (288, 62, 62)
/dev/sda1p3             1         1         0   70  DiskSecure Multi-Boot
Partition 3 has different physical/logical beginnings (non-Linux?):
     phys=(0, 0, 0) logical=(0, 49, 35)
Partition 3 has different physical/logical endings:
     phys=(0, 0, 0) logical=(0, 49, 34)
Partition 3 does not end on cylinder boundary:
     phys=(0, 0, 0) should be (0, 62, 62)
/dev/sda1p4        288321    838117 1073751719+  42  SFS
Partition 4 has different physical/logical beginnings (non-Linux?):
     phys=(73, 0, 0) logical=(288320, 15, 46)
Partition 4 has different physical/logical endings:
     phys=(329, 77, 2) logical=(838116, 19, 60)
Partition 4 does not end on cylinder boundary:
     phys=(329, 77, 2) should be (329, 62, 62)

Partition table entries are not in disk order

# dmesg
hub.c: new USB device 00:10.0-2, assigned address 2
WARNING: USB Mass Storage data integrity not assured
USB Mass Storage device found at 2
SCSI device sda: 3970048 512-byte hdwr sectors (2033 MB)
sda: Write Protect is off
 sda: sda1

Interesting partitions, but it works. Remove and insert CF 1.0 Gb card

# fdisk -l /dev/sda1
# dmesg
sda: Unit Not Ready, sense:
Info fld=0x0, Current 00:00: sns = f0  2
ASC=3a ASCQ= 0
Raw sense data:0xf0 0x02 0x02 0x00 0x00 0x00 0x00 0x0a 0x00 0xaa 0x55 
0x42 0x3a 0x00 0x00 0x00 0x00 0x00
sda : READ CAPACITY failed.
sda : status = 1, message = 00, host = 0, driver = 08
Info fld=0x0, Current sd00:00: sns = f0  2
ASC=3a ASCQ= 0
Raw sense data:0xf0 0x02 0x02 0x00 0x00 0x00 0x00 0x0a 0x00 0xaa 0x55 
0x42 0x3a 0x00 0x00 0x00 0x00 0x00
sda : block size assumed to be 512 bytes, disk size 1GB.
sda: test WP failed, assume Write Enabled
 sda: I/O error: dev 08:00, sector 0
 I/O error: dev 08:00, sector 0
 unable to read partition table

Remove and insert MS 512Mb card,

# fdisk -l /dev/sda1
# dmesg
sda: Unit Not Ready, sense:
Info fld=0x0, Current 00:00: sns = f0  2
ASC=3a ASCQ= 0
Raw sense data:0xf0 0x08 0x02 0x00 0x00 0x00 0x00 0x0a 0x00 0xaa 0x55 
0x48 0x3a 0x00 0x00 0x00 0x00 0x00
sda : READ CAPACITY failed.
sda : status = 1, message = 00, host = 0, driver = 08
Info fld=0x0, Current sd00:00: sns = f0  2
ASC=3a ASCQ= 0
Raw sense data:0xf0 0x08 0x02 0x00 0x00 0x00 0x00 0x0a 0x00 0xaa 0x55 
0x48 0x3a 0x00 0x00 0x00 0x00 0x00
sda : block size assumed to be 512 bytes, disk size 1GB.
sda: test WP failed, assume Write Enabled
 sda: I/O error: dev 08:00, sector 0
 I/O error: dev 08:00, sector 0
 unable to read partition table


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