Hiren's BootCD From USB Flash Drive (USB Pen Drive)

Step 1
Put the BootCD 8 or newer in CD Drive

OR
If you want to extract boot files from iso then Download extract-boot-files
Extract and open readme for more instruction. and skip to step 4

Step 2
Start Mini Windows 98

Step 3
Copy Files From A:\ (Floppy Drive) using Explorer to C:\USB and Restart Computer to normal Windows

OR
Note: if you can not see your hard drive from mini windows 98 then you will need a blank floppy disk.
click Start > Turn Off > Exit to Dos and type COPY A:\*.* B:\
Now remove floppy and Restart Computer to your normal Windows and insert your floppy disk
and copy all files from floppy disk to C:\USB

Step 4
Download USB Disk Storage Format (34KB)

Note: USB Disk Storage Format works on xp, for windows 98 Go to My computer and
Right click on the USB Drive and click on format. You will need a USB Flash Drive 128MB or more

Step 5
Copy All Files From C:\USB to Your USB Flash Drive
Please note: Do not overwrite IO.SYS when it prompts
Delete JO.SYS from USB Drive (NOT IO.SYS)

Step 6
Copy \BOOTCD folder to Your USB Drive

Step 7
Test Your USB Drive

To Enter the BIOS press the "Del" button on your keyboard. Alternatives are "F1", "F2", "Insert", and "F10". Some PC's BIOS might even require a different key to be pressed. Commonly a PC will show a message like "Press [Del] to enter Setup" to indicate that you need to press the "Del" key. Some AMI BIOS require you to enable the option "USB Keyboard Legacy support"!

For AMI BIOS:

• Go to "Feature Setup". "Enable" these options: "USB Function Support",
  "USB Function For DOS" and "ThumbDrive for DOS". Go to "Advanced Setup".
  Set the "1st Boot Device" to "USB RMD-FDD".
  Reboot the PC and it now should boot from the Usb Stick.
• Go to "USB Mass Storage Device Configuration". Select "Emulation Type"
  and set it to "Harddisk". Go to the "Boot Menu" and set the "1st boot device" to "USB-Stick". Exit the BIOS, saving the changes.
  you can try "Emulation Type" to "Floppy" or "Forced FDD".

For PHOENIX/AWARD BIOS:

• Go to "Advanced BIOS Features". Go to the "1st Boot device" and set it to "USB-ZIP".

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If you are having problem while it creates Ram Drive then you may want to edit and delete all the /numhandles=128 from config.sys

Some users reported that it works fine on smaller (128MB) Usb Drives but not on 512MB or larger (cursor blinking at the top left corner)

More Success Reports:
Extract win98-dos (or try winme-dos) files in C:\USB before you use usb_format.exe (Step 4)

Thankx Q from Hiren Boot