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Insert the memory stick into a USB port on your computer. Open Windows Explorer, right click on the drive and choose Format.
NOTE: Before formatting your memory stick, don't forget to backup your files as the process will erase all its contents.
In the Format Removable Disk window choose the NTFS format and click on Start. The other configuration options are not important, the defaults work just fine.
After you formatted the USB stick, create on it two folders named boot and sources
he Recovery and Boot folders on your computer will contain the files needed to be copied on the memory stick.
The first folder is located at 'C:\Recovery'. This folder is used by Windows 7 to load System Recovery tools.
The Boot folder is located at 'C:\Windows\Boot' and its contents is used to boot the operating system.
Both folders are hidden by default. To view them, open Windows Explorer and access Folder Options. In the View tab check 'Show hidden files, folders and drive' and uncheck 'Hide protected operating system files (Recommended)'. Press the Apply button to enable the new settings.
Next, you need to open the Recovery folder on your computer. By default it can't be accessed, even though you are logged on as Administrator. In order to open it, Take Ownership Shortcut How To Put System Repair Tools on the USB Flash
Now you have all the needed files to create the bootable memory stick. First open the Recovery folder. You will notice a sub-folder with an automatically generated name (series of numbers and letters) with a standard length of 32 characters. Open it.
NOTE: The folder name will be different from one PC to another.
Next you have to copy the file boot.sdi to the folder boot from the memory stick.
Then copy the Winre.wim file to the sources folder from the memory stick and rename it to boot.wim.
Now open the folder 'C:\Windows\Boot\DVD\PCAT' and copy the BCD file to the boot folder from the stick.
Go to 'C:\Windows\Boot\DVD\PCAT\en-US' and copy the bootfix.bin file to the folder boot from the USB flash.
Finally, go to C:\Windows\Boot\PCAT and copy the bootmgr file to the root of the memory stick.
DON'T FORGET to test the memory stick .