I am having the same problem trying to create a usb stick containing
Karmic using usb-creator 0.2.7.

I am using the same Sandisk Cruzer Micro 8 GB device as the original
poster. They are widely available here in the U.S. U3 has been turned
off. I sucessfully used this very same usb stick before with an older
version of usb-creator, but I believe I had to format it myself before I
could boot from it--I couldn't use the FAT partition preformatted on the
device to boot from. Now reformatting doesn't solve the problem. It is
being formatted with a geometry of 62 sectors/track, 248 heads/cylinder,
1019 cylinders, which seems like an odd geometry to me.

>From testing so far it appears that the error message is coming from the
ldsyslinix boot record in the first sector of the partition which is
trying to load the rest of ldsyslinux from a file in the FAT partition.
So far I believe the signature test is failing, meaning that the wrong
sector is being loaded. On my system it appears the mbr at the first
sector of the device is not being read and executed by the BIOS, which
itself finds the boot partition as basic partition 1 and loads the boot
sector from the first sector of that partition. I don't know whether or
not the BIOS points the SI register at the partition entry before
transferring control. It seems that the extended BIOS calls are being
used in the boot sector (logical sector number rather than CHS
addressing).

I have a Toshiba L355D-S7825 laptop with an Insyde BIOS, version 1.70.

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When Booted Comes Up With "Boot Error"
https://bugs.launchpad.net/bugs/398241
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