[GH-ISSUE #55] Fails to boot properly on hard disks larger than 137 GB

kerem commented

2026-03-03 18:48:34 +03:00

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Originally created by @roozerxc on GitHub (Sep 13, 2025).
Original GitHub issue: https://github.com/oerg866/win98-quickinstall/issues/55

Computer is a HP Pavilion 563w

CPU: Pentium 4 2.4GHz
MOBO: TriGem Imperial GL VE
RAM: 512MB (2x256MB DDR 400mhz)
HDD: Seagate 160GB 7200rpm IDE HDD
ODD: Sony CRX217E IDE CD-ROM
BIOS was updated to v3.24 (latest available)

I used plop boot manager to boot from a USB stick since installing from a CD gave me multiple BusyBox errors. When installing Windows 98 SE/Me, it first boots to the Windows 9x GUI initially (sometimes a message will pop up asking if you want to keep vpowerd.vxd or some other file) but after a restart the system hangs.

Opening the BOOTLOG.TXT file in edit via the DOS prompt shows me that it's stuck at initializing esdi_506.pdr. Although it did succeed, the machine still hung and completely locked up all input after the Windows 98 splash screen disappeared.

BOOTLOG.TXT

Originally created by @roozerxc on GitHub (Sep 13, 2025). Original GitHub issue: https://github.com/oerg866/win98-quickinstall/issues/55 **Computer is a HP Pavilion 563w** CPU: **Pentium 4 2.4GHz** MOBO: **TriGem Imperial GL VE** RAM: **512MB (2x256MB DDR 400mhz)** HDD: **Seagate 160GB 7200rpm IDE HDD** ODD: **Sony CRX217E IDE CD-ROM** BIOS was updated to v3.24 (latest available) I used plop boot manager to boot from a USB stick since installing from a CD gave me multiple BusyBox errors. When installing Windows 98 SE/Me, it first boots to the Windows 9x GUI initially (sometimes a message will pop up asking if you want to keep `vpowerd.vxd` or some other file) but after a restart the system hangs. Opening the `BOOTLOG.TXT` file in `edit` via the DOS prompt shows me that it's stuck at initializing `esdi_506.pdr`. Although it did succeed, the machine still hung and completely locked up all input after the Windows 98 splash screen disappeared. [BOOTLOG.TXT](https://github.com/user-attachments/files/22308750/BOOTLOG.TXT)

kerem closed this issue

2026-03-03 18:48:34 +03:00

kerem commented

2026-03-03 18:48:35 +03:00

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@oerg866 commented on GitHub (Sep 13, 2025):

Hi, are you saying that with a smaller disk the system boots fine?

On Sat, Sep 13, 2025, 06:45 RoozerXC @.***> wrote:

RoozerXC created an issue (oerg866/win98-quickinstall#55)
https://github.com/oerg866/win98-quickinstall/issues/55

Computer is a HP Pavilion 563w

CPU: Pentium 4 2.4GHz
MOBO: TriGem Imperial GL VE
RAM: 512MB (2x256MB DDR 400mhz)
HDD: Seagate 160GB 7200rpm IDE HDD
ODD: Sony CRX217E IDE CD-ROM
BIOS was updated to v3.24 (latest available)

I used plop boot manager to boot from a USB stick since installing from a
CD gave me multiple BusyBox errors. When installing Windows 98 SE/Me, it
first boots to the Windows 9x GUI initially (sometimes a message will pop
up asking if you want to keep vpowerd.vxd or some other file) but after a
restart the system hangs.

Opening the BOOTLOG.TXT file in edit via the DOS prompt shows me that
it's stuck at initializing esdi_506.pdr. Although it did succeed, the
machine still hung and completely locked up all input after the Windows 98
splash screen disappeared.

BOOTLOG.TXT
https://github.com/user-attachments/files/22308750/BOOTLOG.TXT

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@oerg866 commented on GitHub (Sep 13, 2025): Hi, are you saying that with a smaller disk the system boots fine? On Sat, Sep 13, 2025, 06:45 RoozerXC ***@***.***> wrote: > *RoozerXC* created an issue (oerg866/win98-quickinstall#55) > <https://github.com/oerg866/win98-quickinstall/issues/55> > > *Computer is a HP Pavilion 563w* > > CPU: *Pentium 4 2.4GHz* > MOBO: *TriGem Imperial GL VE* > RAM: *512MB (2x256MB DDR 400mhz)* > HDD: *Seagate 160GB 7200rpm IDE HDD* > ODD: *Sony CRX217E IDE CD-ROM* > BIOS was updated to v3.24 (latest available) > > I used plop boot manager to boot from a USB stick since installing from a > CD gave me multiple BusyBox errors. When installing Windows 98 SE/Me, it > first boots to the Windows 9x GUI initially (sometimes a message will pop > up asking if you want to keep vpowerd.vxd or some other file) but after a > restart the system hangs. > > Opening the BOOTLOG.TXT file in edit via the DOS prompt shows me that > it's stuck at initializing esdi_506.pdr. Although it did succeed, the > machine still hung and completely locked up all input after the Windows 98 > splash screen disappeared. > > BOOTLOG.TXT > <https://github.com/user-attachments/files/22308750/BOOTLOG.TXT> > > — > Reply to this email directly, view it on GitHub > <https://github.com/oerg866/win98-quickinstall/issues/55>, or unsubscribe > <https://github.com/notifications/unsubscribe-auth/AAISOPP5EJBCGGTOBHTMHNL3SOOPTAVCNFSM6AAAAACGMXFM6WVHI2DSMVQWIX3LMV43ASLTON2WKOZTGQYTENJZGEYDEMI> > . > You are receiving this because you are subscribed to this thread.Message > ID: ***@***.***> >

kerem commented

2026-03-03 18:48:35 +03:00

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@roozerxc commented on GitHub (Sep 13, 2025):

Hey oerg, thanks for the followup. Yes, I have gotten Windows 98 SE (Stock) to install and successfully boot on this machine with an 80 GB SATA HDD (Western Digital WD800JD-22MSA1 connected via the StarTech IDE to SATA adapter). However, on drives larger than at least 137 GB (the drive in this machine specifically is a 160GB Seagate Barracuda 7200.7 drive) Windows 98 SE (either Stock or 98Lite) fails to initialize and gets stuck in the boot process after a restart.

Maybe it would be useful to include this patch (HCDP - High Capacity Disk Patch for Win9x) to support larger partitions and hard disk drives during quick-install?

@roozerxc commented on GitHub (Sep 13, 2025): Hey oerg, thanks for the followup. Yes, I have gotten Windows 98 SE (Stock) to install and successfully boot on this machine with an 80 GB SATA HDD (Western Digital WD800JD-22MSA1 connected via the StarTech IDE to SATA adapter). However, on drives larger than at least 137 GB (the drive in this machine specifically is a 160GB Seagate Barracuda 7200.7 drive) Windows 98 SE (either Stock or 98Lite) fails to initialize and gets stuck in the boot process after a restart. Maybe it would be useful to include this patch ([HCDP - High Capacity Disk Patch for Win9x](https://archive.org/details/hcdp_20191002)) to support larger partitions and hard disk drives during quick-install?

kerem commented

2026-03-03 18:48:35 +03:00

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@roozerxc commented on GitHub (Sep 14, 2025):

I forgot to mention pressing F8 and entering Safe mode works and I can use Windows 98 SE, but Normal boot still fails at that "initing esdi_506.pdr" line. Do you happen to know what else (besides the >137 GB size limit) causes this failure?

@roozerxc commented on GitHub (Sep 14, 2025): I forgot to mention pressing F8 and entering Safe mode works and I can use Windows 98 SE, but Normal boot still fails at that "initing esdi_506.pdr" line. Do you happen to know what else (besides the >137 GB size limit) causes this failure?

kerem commented

2026-03-03 18:48:35 +03:00

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@petershaw23 commented on GitHub (Oct 20, 2025):

Can confirm that it gets stuck on boot with my 1500 GB Western Digital, with sata2ide adapter. Manually installing Win98 ("slow "method) and replacing the old ESDI_506.pdr in C:\windows\system\iosubsys with this one is the only fix that seems to work for me
https://www.creopard.de/download/detail/esdi-506-48-bit-lba-korrektur/45.htm
Maybe it could be integrated?

@petershaw23 commented on GitHub (Oct 20, 2025): Can confirm that it gets stuck on boot with my 1500 GB Western Digital, with sata2ide adapter. Manually installing Win98 ("slow "method) and replacing the old ESDI_506.pdr in C:\windows\system\iosubsys with this one is the only fix that seems to work for me https://www.creopard.de/download/detail/esdi-506-48-bit-lba-korrektur/45.htm Maybe it could be integrated?

kerem commented

2026-03-03 18:48:35 +03:00

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@oerg866 commented on GitHub (Oct 21, 2025):

It is already integrated, so that's not the problem.

I'm currently very sick so I don't have the chance to investigate further
at the moment, but as soon as I do I'll update here

On Mon, Oct 20, 2025, 23:17 petershaw23 @.***> wrote:

petershaw23 left a comment (oerg866/win98-quickinstall#55)
https://github.com/oerg866/win98-quickinstall/issues/55#issuecomment-3423753630

Can confirm that it gets stuck on boot with my 1500 GB Western Digital,
with sata2ide adapter. Manually installing Win98 ("slow "method) and
replacing the old ESDI_506.pdr in C:\windows\system\iosubsys with this one
is the only fix that seems to work for me
https://www.creopard.de/download/detail/esdi_506/45.htm
Maybe it could be integrated?

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@oerg866 commented on GitHub (Oct 21, 2025): It is already integrated, so that's not the problem. I'm currently very sick so I don't have the chance to investigate further at the moment, but as soon as I do I'll update here On Mon, Oct 20, 2025, 23:17 petershaw23 ***@***.***> wrote: > *petershaw23* left a comment (oerg866/win98-quickinstall#55) > <https://github.com/oerg866/win98-quickinstall/issues/55#issuecomment-3423753630> > > Can confirm that it gets stuck on boot with my 1500 GB Western Digital, > with sata2ide adapter. Manually installing Win98 ("slow "method) and > replacing the old ESDI_506.pdr in C:\windows\system\iosubsys with this one > is the only fix that seems to work for me > https://www.creopard.de/download/detail/esdi_506/45.htm > Maybe it could be integrated? > > — > Reply to this email directly, view it on GitHub > <https://github.com/oerg866/win98-quickinstall/issues/55#issuecomment-3423753630>, > or unsubscribe > <https://github.com/notifications/unsubscribe-auth/AAISOPLG5CQK3N2FU2EAVJD3YVGPHAVCNFSM6AAAAACGMXFM6WVHI2DSMVQWIX3LMV43OSLTON2WKQ3PNVWWK3TUHMZTIMRTG42TGNRTGA> > . > You are receiving this because you commented.Message ID: > ***@***.***> >

kerem commented

2026-03-03 18:48:35 +03:00

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@the-r3dacted commented on GitHub (Feb 5, 2026):

Can confirm that it gets stuck on boot with my 1500 GB Western Digital, with sata2ide adapter. Manually installing Win98 ("slow "method) and replacing the old ESDI_506.pdr in C:\windows\system\iosubsys with this one is the only fix that seems to work for me https://www.creopard.de/download/detail/esdi-506-48-bit-lba-korrektur/45.htm Maybe it could be integrated?

I have this issue as well and this was the fix for me as well.

@the-r3dacted commented on GitHub (Feb 5, 2026): > Can confirm that it gets stuck on boot with my 1500 GB Western Digital, with sata2ide adapter. Manually installing Win98 ("slow "method) and replacing the old ESDI_506.pdr in C:\windows\system\iosubsys with this one is the only fix that seems to work for me https://www.creopard.de/download/detail/esdi-506-48-bit-lba-korrektur/45.htm Maybe it could be integrated? I have this issue as well and this was the fix for me as well.

kerem commented

2026-03-03 18:48:35 +03:00

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@the-r3dacted commented on GitHub (Feb 5, 2026):

Nevermind, it booted fine once after I replaced the file, but now the issue is back.

@the-r3dacted commented on GitHub (Feb 5, 2026): Nevermind, it booted fine once after I replaced the file, but now the issue is back.

kerem commented

2026-03-03 18:48:35 +03:00

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@yum13241 commented on GitHub (Feb 10, 2026):

This is an infamous Legacy BIOS limitation.

@yum13241 commented on GitHub (Feb 10, 2026): This is an infamous Legacy BIOS limitation.

kerem commented

2026-03-03 18:48:35 +03:00

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@oerg866 commented on GitHub (Feb 11, 2026):

Which is patched by ESDI_506.PDR update... New version should have this bug fixed when it is released (end of week probably)

@oerg866 commented on GitHub (Feb 11, 2026): Which is patched by ESDI_506.PDR update... New version should have this bug fixed when it is released (end of week probably)

kerem commented

2026-03-03 18:48:35 +03:00

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@yum13241 commented on GitHub (Feb 11, 2026):

This is because all the BIOS needs access to is the beginning of the disk anyway.
Lots of old BIOSes don't have support for accessing beyond the 28-bit LBA boundary, which is 128GiB or 137GB.
These days, BIOSes use 48-bit LBA-,LBA48,-%5Bedit%5D).

If this is all gobbledygook to you, look up "legacy bios 137gb" using your favorite search engine.
https://duckduckgo.com/?q=legacy+BIOS+137gb&ia=web
https://easy2boot.xyz/troubleshooting-e2b/the-128gib-137gb-usb-bios-bug/
https://retrocomputing.stackexchange.com/questions/19622/how-can-i-tell-if-my-old-pc-supports-137-gb-hard-drives
https://forums.justlinux.com/showthread.php?148354-Does-USB-Legacy-has-a-137GB-limit
https://www.wimsbios.com/forum/viewtopic.php?t=9022&p=43329

Most OSes these days don't use BIOS disk access routines anyway, except at boot times.
Obviously, Windows 98 is not a modern OS and still relies a ton on BIOS disk access routines, hell, W95's IDE disk drive wouldn't boot if your boot disk went beyond the aforementioned limit.

I'm assuming this ESDI_506.PDR update is some sort of custom drive that uses directly accesses the hardware instead of BIOS interrupts.

@yum13241 commented on GitHub (Feb 11, 2026): This is because all the BIOS needs access to is the beginning of the disk anyway. Lots of old BIOSes don't have support for accessing beyond the 28-bit LBA boundary, which is 128GiB or 137GB. These days, BIOSes use [48-bit LBA](https://en.wikipedia.org/wiki/Logical_block_addressing#:~:text=63%20%C3%97%20255%20%C3%97%20512)-,LBA48,-%5Bedit%5D). If this is all gobbledygook to you, look up "legacy bios 137gb" using your favorite search engine. https://duckduckgo.com/?q=legacy+BIOS+137gb&ia=web https://easy2boot.xyz/troubleshooting-e2b/the-128gib-137gb-usb-bios-bug/ https://retrocomputing.stackexchange.com/questions/19622/how-can-i-tell-if-my-old-pc-supports-137-gb-hard-drives https://forums.justlinux.com/showthread.php?148354-Does-USB-Legacy-has-a-137GB-limit https://www.wimsbios.com/forum/viewtopic.php?t=9022&p=43329 Most OSes these days don't use BIOS disk access routines anyway, except at boot times. Obviously, Windows 98 is not a modern OS and still relies a ton on BIOS disk access routines, hell, W95's IDE disk drive wouldn't boot if your boot disk went beyond the aforementioned limit. I'm assuming this `ESDI_506.PDR` update is some sort of custom drive that uses directly accesses the hardware instead of BIOS interrupts.

kerem commented

2026-03-03 18:48:35 +03:00

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@oerg866 commented on GitHub (Feb 11, 2026):

I know you mean well, but I'm well aware of these things including the
technical details and the bios is not the limiting factor here :)

ESDI_506 is win9x's ATA disk driver which is bug infested and needs a
million patches to work properly, it does not use int13h to talk to the
disk at all

On Wed, Feb 11, 2026, 11:21 yum13241 @.***> wrote:

yum13241 left a comment (oerg866/win98-quickinstall#55)
https://github.com/oerg866/win98-quickinstall/issues/55#issuecomment-3883513726

This is because all the BIOS needs access to is the beginning of the disk
anyway.
Lots of old BIOSes don't have support for accessing beyond the 28-bit LBA
boundary, which is 128GiB or 137GB.
These days, BIOSes use 48-bit LBA
https://en.wikipedia.org/wiki/Logical_block_addressing#:~:text=63%20%C3%97%20255%20%C3%97%20512
-,LBA48,-%5Bedit%5D).

If this is all gobbledygook to you, look up "legacy bios 137gb" using your
favorite search engine.
https://duckduckgo.com/?q=legacy+BIOS+137gb&ia=web
https://easy2boot.xyz/troubleshooting-e2b/the-128gib-137gb-usb-bios-bug/

https://retrocomputing.stackexchange.com/questions/19622/how-can-i-tell-if-my-old-pc-supports-137-gb-hard-drives

https://forums.justlinux.com/showthread.php?148354-Does-USB-Legacy-has-a-137GB-limit
https://www.wimsbios.com/forum/viewtopic.php?t=9022&p=43329

Most OSes these days don't use BIOS disk access routines anyway, except at
boot times.
Obviously, Windows 98 is not a modern OS and still relies a ton on BIOS
disk access routines, hell, W95's IDE disk drive wouldn't boot if your boot
disk went beyond the aforementioned limit.

I'm assuming this ESDI_506.PDR update is some sort of custom drive that
uses directly accesses the hardware instead of BIOS interrupts.

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@oerg866 commented on GitHub (Feb 11, 2026): I know you mean well, but I'm well aware of these things including the technical details and the bios is not the limiting factor here :) ESDI_506 is win9x's ATA disk driver which is bug infested and needs a million patches to work properly, it does not use int13h to talk to the disk at all On Wed, Feb 11, 2026, 11:21 yum13241 ***@***.***> wrote: > *yum13241* left a comment (oerg866/win98-quickinstall#55) > <https://github.com/oerg866/win98-quickinstall/issues/55#issuecomment-3883513726> > > This is because all the BIOS needs access to is the beginning of the disk > anyway. > Lots of old BIOSes don't have support for accessing beyond the 28-bit LBA > boundary, which is 128GiB or 137GB. > These days, BIOSes use 48-bit LBA > <https://en.wikipedia.org/wiki/Logical_block_addressing#:~:text=63%20%C3%97%20255%20%C3%97%20512> > -,LBA48,-%5Bedit%5D). > > If this is all gobbledygook to you, look up "legacy bios 137gb" using your > favorite search engine. > https://duckduckgo.com/?q=legacy+BIOS+137gb&ia=web > https://easy2boot.xyz/troubleshooting-e2b/the-128gib-137gb-usb-bios-bug/ > > https://retrocomputing.stackexchange.com/questions/19622/how-can-i-tell-if-my-old-pc-supports-137-gb-hard-drives > > https://forums.justlinux.com/showthread.php?148354-Does-USB-Legacy-has-a-137GB-limit > https://www.wimsbios.com/forum/viewtopic.php?t=9022&p=43329 > > Most OSes these days don't use BIOS disk access routines anyway, except at > boot times. > Obviously, Windows 98 is not a modern OS and still relies a ton on BIOS > disk access routines, hell, W95's IDE disk drive wouldn't boot if your boot > disk went beyond the aforementioned limit. > > I'm assuming this ESDI_506.PDR update is some sort of custom drive that > uses directly accesses the hardware instead of BIOS interrupts. > > — > Reply to this email directly, view it on GitHub > <https://github.com/oerg866/win98-quickinstall/issues/55#issuecomment-3883513726>, > or unsubscribe > <https://github.com/notifications/unsubscribe-auth/AAISOPP5JX6TPMPFYFV64ZT4LL7BLAVCNFSM6AAAAACGMXFM6WVHI2DSMVQWIX3LMV43OSLTON2WKQ3PNVWWK3TUHMZTQOBTGUYTGNZSGY> > . > You are receiving this because you commented.Message ID: > ***@***.***> >

kerem commented

2026-03-03 18:48:36 +03:00

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@yum13241 commented on GitHub (Feb 14, 2026):

I know you mean well

Thanks.

but I'm well aware of these things including the
technical details and the bios is not the limiting factor here :)

I'll just take your word for it.

ESDI_506 is win9x's ATA disk driver which is bug infested and needs a
million patches to work properly, it does not use int13h to talk to the
disk at all

So buggy direct disk access? Not unexpected.

@yum13241 commented on GitHub (Feb 14, 2026): > I know you mean well Thanks. > but I'm well aware of these things including the technical details and the bios is not the limiting factor here :) I'll just take your word for it. > ESDI_506 is win9x's ATA disk driver which is bug infested and needs a million patches to work properly, it does not use int13h to talk to the disk at all So buggy direct disk access? Not unexpected.

kerem commented

2026-03-03 18:48:36 +03:00

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@oerg866 commented on GitHub (Feb 15, 2026):

Closing this for now; If still present on 1.0.0 reopen a new issue pls thanks!

@oerg866 commented on GitHub (Feb 15, 2026): Closing this for now; If still present on 1.0.0 reopen a new issue pls thanks!

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[GH-ISSUE #55] Fails to boot properly on hard disks larger than 137 GB #50