The file "install.wim" is too large for the destination file system.

I just checked the MCT and it is still offering the original March release 15063.0 of Windows 10. The new June refresh MSDN ISO is version 15063.413 and as you have found will not fit on a FAT32 formatted flash drive because of the 4.0GB file size limit of FAT32.

For UEFI installs you need a bootable FAT partition. I know you are not a fan of Rufus but it can solve this issue. It can create a very small FAT12 bootable partition and the rest of the flash drive will be formatted NTFS for data. I have actually made a flash drive of this type and it works as advertised.

Here are my settings for Rufus:



Your settings may be different depending on your system setup. The yellow highlighted area is the important one related to this issue.

Here is my flash drive:

tracit99 said:

I just checked the MCT and it is still offering the original March release 15063.0 of Windows 10. The new June refresh MSDN ISO is version 15063.413 and as you have found will not fit on a FAT32 formatted flash drive because of the 4.0GB file size limit of FAT32.

For UEFI installs you need a bootable FAT partition. I know you are not a fan of Rufus but it can solve this issue. It can create a very small FAT12 bootable partition and the rest of the flash drive will be formatted NTFS for data. I have actually made a flash drive of this type and it works as advertised.

Here are my settings for Rufus:



Your settings may be different depending on your system setup. The yellow highlighted area is the important one related to this issue.

Here is my flash drive:

This Rufus method should work in any computer with UEFI firmware. Another method is simply to format the UFD witn NTFS, mount the ISO and copy its contents to the UFD. But this may not work in some computers.

Another option is to load NTFS EFI drivers (See The rEFInd Boot Manager: Using EFI Drivers) or boot from PE and install with DISM.

Hi,
@lx07 : Isn't that what Rufus is using ?

In order Rufus to work (i.e. create a second partition) to work you'd need a flash drive that supports it, such as that Sandisk Glide, correct ?

Cheers,

fdegrove said:

Hi,
@lx07 : Isn't that what Rufus is using ?

In order Rufus to work (i.e. create a second partition) to work you'd need a flash drive that supports it, such as that Sandisk Glide, correct ?

Cheers,

I think that is what Rufus does, yes, makes a FAT partition with EFI NTFS drivers then NTFS partition.

What I meant was you could boot from FAT formatted PE rescue disk (or you could put bootloader like rEFInd instead) and then install Windows from a separate NTFS USB containing the .wim. This method would be a bit redundant now I suppose as I saw this describing setting up on one USB

WinPE: Create USB Bootable drive | Microsoft Docs

You can partition any flash drive with multiple partitions - no need for a special type. At least I've never had any refuse. The only issue AFAIK is Windows prior to 1703 would only recognize the first partition unless it the drive was seen as fixed.

Hi,

You can partition any flash drive with multiple partitions - no need for a special type. At least I've never had any refuse. The only issue AFAIK is Windows prior to 1703 would only recognize the first partition unless it the drive was seen as fixed.

Thanks for that. I wasn't aware MS fixed that. I had the impression it was hardware dependent.

Cheers,

Hi,

If the media Creation Tool remains fat32 compatible it won't be a big issue for most.

Surely MS is aware of that. IP installs keep on having smaller and smaller footprints.
OTOH, MCT created media or ISO are only good for installing the OS. Ideally you'd want a .WIM file as @Superfly has pointed out.

Cheers,