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Problem booting MSDOS from grub on USB-stick

From: pdj
Subject: Problem booting MSDOS from grub on USB-stick
Date: Fri, 20 Mar 2009 15:06:56 +0100 (CET)
User-agent: SquirrelMail/1.4.15


I've made a multiboot USB-stick with MSDOS, MemTest86+ and RIPLinux using
grub as the boot manager.

Grub starts fine and can boot into RIPLinux as well as MemTest86+ in all
cases - Only the MSDOS seems to have problems on some machines, resulting
in the following output:
Starting up ...

Non-System disk or disk error
Replace and press any key when ready

The disk geometry seems to be incorrect on the troubled machine. I suppose
this is the reason why MSDOS will not start.

Can anyone confirm that this is in fact the problem, and maybe direct me
to a solution?

grub geometry on troubled machine:
grub> geometry (hd0)
drive 0x80: C/H/S = 1024/63/32, The number of sectors = 4057088, LBA
   Partition num: 0 Filesystem type is fat, partition type 0x6
   Partition num: 1 Filesystem type is ext2fs, partition type 0x83
   Partition num: 4 Filesystem type is fat, partition type 0x6

My set-up:
# fdisk -l /dev/sdb
Disk /dev/sdb: 2077 MB, 2077229056 bytes
255 heads, 63 sectors/track, 252 cylinders
Units = cylinders of 16065 * 512 = 8225280 bytes
Disk identifier: 0x00000000

   Device Boot      Start         End      Blocks   Id  System
/dev/sdb1   *           1           7       56196    6  FAT16
/dev/sdb2               8           8        8032+  83  Linux
/dev/sdb3               9         252     1959930    5  Extended
/dev/sdb5               9          21      104391    6  FAT16

sdb1 holds an MSDOS 6.22 boot partition.
sdb2 holds grub (and memtest86+)
sdb5 holds RIPLinux

default 0

title   DOS 6.22
  rootnoverify (hd0,0)
  chainloader +1

title   MemTest86+ v2.10
  kernel (hd0,1)/boot/memtest86+-2.10.bin

title   RIPLinuX v7.8
  root (hd0,4)
  kernel /kernel vga=normal
  initrd /rootfs.cgz


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