USB booting :: Cant find KNOPPIX file

After trying to get the USB booting faster by using the initrd version of DSL (loading the initrd and KNOPPIX file in RAM), Im now back again to the "standard" embedded version. Just feels faster to mount the KNOPPIX filesystem that loading it into RAM from slow USB motherboards.

My problem is that after Kernel and minirt24 loads and linuxrc starts executing, the USB stick dies (light go out) and never returns. With some BIOSes I have to power cycle the motherboard to get it working again!!
I pass the "fromusb" param and see the usbcore etc modules loaded, but because the stick is dead I just end up with the "Cant find KNOPPIX file" error.
If Im lucky I can, while linuxrc script detects USB devices, unplug and re-connect the stick to get it working again - it finds filesystem on /dev/sda1 and it boots fine. But this rarely works.

So, are the usb modules broken? It seems to die when the usb modules are loaded (I think).

How can I debug further?

There might be some complication with the mobo, or the stick is close to breaking..

Im trying now on diff motherboard and diff stick - still same behavior.
It does go through without hitch about 1 in 10 times I try. Timing of USB maybe?
I see the minird usb modules are diff than the ones in KNOPPIX file?

Prob faulty mobo or stick, I now get read errors on access of cloop-ed KNOPPIX image.

This is really freaky - new mobo, new stick - linuxrc picks up stick every 1 in 8 times (roughly).

?

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