Boot Camp 'Your bootable USB drive could not be created' error

I have a Mac Mini with OS X version 10.8 and Boot Camp version 5. I am trying to create a bootable USB drive using Boot Camp. I am using a Windows 7 Pro iso file and a 4 GB flash drive to create it. I select 'Create a Windows 7 install disk' along with the other two selections. Everytime I try it, I get the same error message of: Your bootable USB drive could not be created. An error occurred while formatting the disk.

Could this be a bad flash drive or a software error?

Mac mini, OS X Mountain Lion

Posted on Aug 5, 2012 5:44 AM

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Loner T

Level 9

59,536 points

Posted on Sep 7, 2017 5:47 AM

If the install.wim or boot.wim file on the ISO is larger than 4GB, then BCA does not copy the file to the USB since FAT32 file size limit is 4GB. This is usually the case when you have mixed 32-bit/64-bit ISO or multiple Windows variants in a single WIM file.

As a test Download Windows 10 Disc Image (ISO File) and use BCA and check if it works.

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90 replies

omingoke

Level 1

0 points

Nov 9, 2015 7:31 PM in response to Loner T

Will try to download, thanks for the support.

I'll let you know the result

Nov 15, 2015 4:29 AM in response to omingoke

any updates?

Loner T

Level 9

59,536 points

Dec 17, 2015 2:51 PM in response to mikethemartian

Connect the USB and post the output of

diskutil list

sudo fdisk /dev/diskN - where N points to the USB as shown by the previous command.

Dec 17, 2015 3:27 PM in response to Loner T

So I have done that, what is the next step?

Thanks

Mike

Loner T

Level 9

59,536 points

Dec 17, 2015 3:35 PM in response to mikethemartian

Can you post the output of the two commands?

Dec 17, 2015 5:13 PM in response to Loner T

I assume you meant disk4, and I do get the asterisk. I'll let you know if the install is successful.

Thanks again for all your help

Loner T

Level 9

59,536 points

Dec 17, 2015 5:25 PM in response to mikethemartian

Yes, disk4 was the intended target. If you have any issues, please post back.

EEEGUU

Level 1

0 points

Dec 23, 2015 12:40 PM in response to JakobGK

You are awesome !!

I spent 3 days cursing at my mac and trying 255220 different solution and you nailed it !!

Thank you so much !!

Jul 14, 2017 3:42 AM in response to RA_Mac_Book_User

I keep getting "Your bootable USB drive could not be created" and can't find the answer. I've been looking through this thread but nothing seems to help.

Loner T

Level 9

59,536 points

Jul 14, 2017 4:40 AM in response to AppleUser_Ken

What is the year/model of your Mac? What type of a USB drive are you using - flash or external hdd?

Jul 15, 2017 7:46 PM in response to Loner T

Early 2013 MacBook Air USB: External (I believe)

Jul 15, 2017 7:49 PM in response to Loner T

Sorry for the late reaponse

Jul 15, 2017 8:34 PM in response to Loner T

Oh by the way. Don't worry about it. I found a new USB and it's working fine

Loner T

Level 9

59,536 points

Sep 7, 2017 5:58 AM in response to steedoc

Format it as shown..

Loner T

Level 9

59,536 points

Sep 7, 2017 6:50 PM in response to steedoc

The ISO itself may be over 4GB, but only files are copied to the USB. If you mount the ISO, can you check the size of install.wim?

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Boot Camp 'Your bootable USB drive could not be created' error