Solved A disk read error occured on external USB HDD

[Nugroho]

I install Windows XP to external USB HDD and Windows 7 to other USB HDD.
I have been using boot from ext. USB HDD for years because internal HDD is too small at that time and I keep it that way until recently I got problem.

I change from Dell620 to HP8560 and immediately it cannot boot from WinXP on USB. The only message is "A disk read error occured. Press Ctrl-Alt-Del to restart". I try to install again without any error during the installation process, but same error once it boot from ext USB HDD.
I still can boot Win7 on other ext. USB HDD. I upgrade it to Win8 Release Preview and work smoothly. When Win8 RP expired, I keep using it without upgrade because I usually use it for less than 2 hours.
Suddenly it cannot boot again like WinXP on other USB HDD. "A disk read error occured." I cannot find anything wrong with USB HDD.
I can still access all files on USB HDD from any system. I just cannot boot from it.

How can I know if this is hardware defect or recently Windows apply patch/update that make it cannot boot from USB anymore ?

 

[gregrocker]

Windows is not meant to boot from a USB HDD. Install the HD internally or via SATA converter cable, then run Paragon Virtualization Manager to adjust it to the new hardware.

 

[Nugroho]

It was working well. I mean I can boot from USB HDD for more than a year without any problem.
Suddenly I cannot boot anymore from that USB HDD. If I boot to internal HDD, can still access all files in that USB HDD.
I try to install again the OS like what I did before but no success.
May be the boot sector is bad? But I still can read and write (restore) boot sector without error.

 

[Nugroho]

I boot from flash disk with Grub. I try to boot by loading bootmgr but Grub report file not found.
Is it necessary to put bootmgr on certain sector or the first few cylinders?

 

[Nugroho]

I found the root cause. I defrag, and put boot loader and boot folder at the beginning of the disk. Now I can boot from USB external hard disk again.
I wonder if the Windows folder must put in the first 128Gb area too.