Problems Creating Recovery Drive On Win 11 Pro Computer

Hi All -
I have had a huge problem with updating a recovery drive. This is on my system 1 Windows 11 Pro computer in my profile. When it was new, one of the first things I did was create a recovery drive. No problem. It was on a SanDisk Ultra 32GB flash drive, which I still have. I want to keep that as a backup, but it doesn't have two years of system updates on it. That was done when the current version was at 22H2. I have updated my system each time it was available, and am now on 25H2 (which seems to run OK at present)! I read where it is good to update your recovery drive each year, so I decided to try a new drive, but since I have read that a 32GB drive is not really 32GB, but less, I bought a 64GB Lexar flash drive and tried to create a recovery drive with it. I had disconnected all my other USB drives, and fired up my computer, And got this:


So, I clicked "Next," and got this:



The computer wasn't recognizing the drive in this program. So, I tried formatting the 64GB flash drive in FAT32. I was unable to do that, as the only choices were EX-FAT, and NTFS. I read that you could format the drive to FAT32 in a command prompt, and there was a command where I had to substitute the drive letter for X in the example. I did that, and it took a while, but when I looked at the drive's properties it said FAT32. Great, right? Except that computer still did not recognize the drive in the utility. I returned the 64GB drive, and figured that the original recovery drive was 32GB, so I went and bought the same make (SanDisk) and model and tried it. Same result, only this time, I could format FAT32 without a problem, but still no joy. I returned the drive to the store and got a 128GB PNY drive, as I had used that on my other new Win 11 Pro computer without a problem, or issue. I checked with Google's AI, and it said that I could possibly get the recovery drive made by unchecking the box said "back up system files in the recovery drive:"



So, I tried that, and I could see the recovery drive, by clicking "Next."
I clicked "Next" on the following page, and it formatted the drive as FAT32.
Here is the screenshot of the properties:



So, I go back in and set up to start to create a recovery drive, and the utility will still not recognize this drive.

Has anyone run into this before, and if so, how did you fix it? I have come to the conclusion that it is not the drives, but my computer. I don't wish to purchase any new programs for backup, as my budget is thin. Is there some way I can get my computer to recognize the flash drive, and make a recovery drive from this drive, as I really don't want to return this drive to the store?

Thanks.

archfoto said:

I read where it is good to update your recovery drive each year

Click to expand...

I have a small tray of Windows Recovery USB sticks. I randomly take one out. One is a Windows 8.1 Recovery, Windows 10 & a Windows 11, all work on Windows 11.

archfoto said:

but it doesn't have two years of system updates on it

Click to expand...

System updates being placed on a recovery drive is new to me. I actually never looked in a recovery USB.

I believe you have a misunderstanding about what a recovery drive is. It a bootable USB stick or other media containing Windows Recovery Environment(WinRE) tools like Startup Repair and System Restore. It is NOT a backup of your complete Windows OS. One can also access these same recovery tools using a Windows Installation usb. Using a 32 gb usb is a big overkill for a recovery drive. You can create a full windows install disk on a 8gb usb.

archfoto said:

I don't wish to purchase any new programs for backup,

Click to expand...

Hasleo Backup Suite is free. It can image your entire system to external media; OS, applications, user files, everything. Hasleo provides Windows Backup & Clone, Data Recovery, Windows To Go Creator, and more.
You create a Hasleo usb boot drive (4gb or larger)from within Hasleo once it is installed. This boot drive allows you to recover your entire system.

@archfoto
the FAT32 format has a partition limit of 32GB
for the recovery drive please try NTFS.

best of luck Steve ..

antspants said:

I have a small tray of Windows Recovery USB sticks. I randomly take one out. One is a Windows 8.1 Recovery, Windows 10 & a Windows 11, all work on Windows 11.



System updates being placed on a recovery drive is new to me. I actually never looked in a recovery USB.

Click to expand...

Hi Antspants -
Yeah, according to what I have read, all of your updates and drivers will be included in recovering just Windows, so that if I used the original recovery drive I made when the computer was new, it wouldn't have any of those updates, and I would have to update constantly to catch up. Also, I found out that if you have an old Win 10 computer, and you want to have the last updates, since MS won't provide those, you have to have them backed up, or you start with the oldest version!

archfoto said:

according to what I have read, all of your updates and drivers will be included in recovering just Windows,

Click to expand...

As I said, you are misunderstanding what a recovery drive is and exactly what it can do.

glasskuter said:

I believe you have a misunderstanding about what a recovery drive is. It a bootable USB stick or other media containing Windows Recovery Environment(WinRE) tools like Startup Repair and System Restore. It is NOT a backup of your complete Windows OS. One can also access these same recovery tools using a Windows Installation usb. Using a 32 gb usb is a big overkill for a recovery drive. You can create a full windows install disk on a 8gb usb.

Hasleo Backup Suite is free. It can image your entire system to external media; OS, applications, user files, everything. Hasleo provides Windows Backup & Clone, Data Recovery, Windows To Go Creator, and more.
You create a Hasleo usb boot drive (4gb or larger)from within Hasleo once it is installed. This boot drive allows you to recover your entire system.

Click to expand...

Hi Glasskuter -
Yeah, I understand that. This, to me, is just somewhat of an insurance policy. I have used the Windows restore feature from the restore points a few times, and it has gotten me back on track, and thank goodness, I have not had to use the recovery drive, ever. I just want to know why my computer can recognize the flashdrives among the other USB drives I have in "My PC," but not in the recovery drive utility. I just created a recovery drive a little while back on my wife's old Win 10 Pro computer using a Lexar 64GB drive with no problems, as I will probably think about selling it down the road, sans any of our information. It has all the updates until support was stopped by MS. Thanks for the tip on Hasleo.

XxXxX said:

@archfoto
the FAT32 format has a partition limit of 32GB
for the recovery drive please try NTFS.

best of luck Steve ..

Click to expand...

Hi XxXxX -

Apparently, the utility will format the drive only in FAT32! I have also tried starting out in NTFS!

archfoto said:

Hi Antspants -
Yeah, according to what I have read, all of your updates and drivers will be included in recovering just Windows, so that if I used the original recovery drive I made when the computer was new, it wouldn't have any of those updates, and I would have to update constantly to catch up. Also, I found out that if you have an old Win 10 computer, and you want to have the last updates, since MS won't provide those, you have to have them backed up, or you start with the oldest version!

Click to expand...

Like glasskuter says, I believe you’re confusing a Windows recovery USB (for troubleshooting) to a System “Image”
What you’re showing in the first post is a recovery USB to boot to so as you can run troubleshooting etc

It isn't bad to update a Recovery drive yearly or so. Maybe the utility includes more files with zeroes just to boast, but every new Recovery drive I've done (all successfully) has higher occupied space.

If you choose FAT32 to format any USB stick with enough capacity (64 GB, 128 GB, 1,048,576 PB, etc), Diskmgmt will shrink any previous partition to about 31.9 GB, which is NOT enough to recognize the media as valid for a Recovery drive.

You don't have to format anything, unless you've done erroeous formats like the one of the previous paragraph, in which case you have to enlarge the partition before.

I have never fixed it with Diskmgmt (Idk if it can be done), I use 3rd party managers instead, normally MiniTool Free except MiniTool paid in one of my computers, but any should do.

With a 3rd party partition app, pick any USB stick w/o important data and with exactly "64 GB" commercially (I have doubts about if it can be done on a 128 GB one in general or in your computer after reading your posts, and I have always used 64 GB anyway), DELETE any partition it has and leave the USB drive unallocated, CREATE a new partition with any filesystem different from FAT, FAT16 and FAT32 (maybe exFAT, my favourite one for pendrives, is better than NTFS in your computer for any odd reason, but NTFS should work too, I prefer exFAT for my pendrives with data b/c it's totally passive and very accurate with the files dates, but you'll lose this format when you do the Recovery drive anyway).

The Recovery drive program will delete any data or partition, it will create a FAT32 partition with exactly 32 GB, and the Recovery disk in it.

archfoto said:

I tried formatting the 64GB flash drive in FAT32. I was unable to do that

Click to expand...

Use a tool such as Minitool partition wizard to do the Fat32 formatting.
Windows is able to work with such large Fat32 partitions; it's just the >32GB formatting task that Windows cannot handle.

You were right to set the checkbox for

archfoto said:

back up system files in the recovery drive

Click to expand...

Without that setting a Recovery drive is about the same as a System repair disk.
There are several incorrect statements about Recovery drives in this thread. What you were trying to do when you started was correct.
Create Recovery Drive - ElevenForumTutorials


Denis

This is a link for recovery drive:



This is link for bootable USB:



This is a link for backup imaging:

JLArranz said:

It isn't bad to update a Recovery drive yearly or so. Maybe the utility includes more files with zeroes just to boast, but every new Recovery drive I've done (all successfully) has higher occupied space.

If you choose FAT32 to format any USB stick with enough capacity (64 GB, 128 GB, 1,048,576 PB, etc), Diskmgmt will shrink any previous partition to about 31.9 GB, which is NOT enough to recognize the media as valid for a Recovery drive.

You don't have to format anything, unless you've done erroeous formats like the one of the previous paragraph, in which case you have to enlarge the partition before.

I have never fixed it with Diskmgmt (Idk if it can be done), I use 3rd party managers instead, normally MiniTool Free except MiniTool paid in one of my computers, but any should do.

With a 3rd party partition app, pick any USB stick w/o important data and with exactly "64 GB" commercially (I have doubts about if it can be done on a 128 GB one in general or in your computer after reading your posts, and I have always used 64 GB anyway), DELETE any partition it has and leave the USB drive unallocated, CREATE a new partition with any filesystem different from FAT, FAT16 and FAT32 (maybe exFAT, my favourite one for pendrives, is better than NTFS in your computer for any odd reason, but NTFS should work too, I prefer exFAT for my pendrives with data b/c it's totally passive and very accurate with the files dates, but you'll lose this format when you do the Recovery drive anyway).

The Recovery drive program will delete any data or partition, it will create a FAT32 partition with exactly 32 GB, and the Recovery disk in it.

Click to expand...

Hi JLArranz -
I did not choose FAT32, the program did, when I formatted the flashdrive with the utility. And you are right, the partition goes to 31.9GB. What I want to know, primarily, since some of the other members have given me ways to actually back up my main hard drive or create a bootable USB drive, and I also have several terabytes of hard drive space on external USB drives to do so, is why I was able to make a recovery stick when the computer was new, but why it refuses to do so now, by not recognizing the drive within the utility, even though it was able to format it.

zbook said:

This is a link for recovery drive:

Create Recovery Drive in Windows 11

This tutorial will show you how to create a bootable USB recovery drive that boots to advanced startup (WinRE) to troubleshoot, restore, or recover Windows 11. If your PC won’t start, you can use a recovery drive to restore from a system restore point or recover your PC. It's a good idea to...

www.elevenforum.com

This is link for bootable USB:

Create Windows 11 Bootable USB Installation Media

This tutorial will show you how to create a bootable USB flash drive used to install Windows 11 with UEFI support. You can use a Windows 11 installation USB flash drive to clean install, upgrade, reset, or repair Windows 11. The installation USB can also be used as a recovery drive to boot to...

www.elevenforum.com

This is a link for backup imaging:

Backup and Restore with Macrium Reflect

How to Create and Restore a System Image Backup with Macrium Reflect

www.tenforums.com

Click to expand...

Hi Zbook -

Thanks for the links!

archfoto said:

Hi JLArranz -
I did not choose FAT32, the program did, when I formatted the flashdrive with the utility. And you are right, the partition goes to 31.9GB. What I want to know, primarily, since some of the other members have given me ways to actually back up my main hard drive or create a bootable USB drive, and I also have several terabytes of hard drive space on external USB drives to do so, is why I was able to make a recovery stick when the computer was new, but why it refuses to do so now, by not recognizing the drive within the utility, even though it was able to format it.

Click to expand...

A computer or the programs are automatons. If it recognized the USB drive you used time ago as capable of being a Recovery disk, it was b/c the drive had a recognizable 32 GB or larger partition (others here may know more than me about how the involved automatons behave -an OS can have millions of instructions, not just 2 or 3-, I have a diffuse memory that formatting a partition in FAT32 with more than 32 GB requires tricks, and tricks are prone to work for some concrete things but not for others: you know that formatting in FAT32 with Diskmgmt gives a 31.9 GB partition, and when you finally get the Recovery drive you'll see it's a 32 GB partition, so 31.9 or 32, does Windows have double personality or what??? depending on what and the details you watch you can notice hundreds or millions of "personalities", software science calls them procedures, functions, methods, objects, classes, dlls,... any big program has many, and we've detected 2 here: one that formats 31.9 GB, and other that first requires 32 GB or more and after formats 32 GB, not 31.9).

Why did it work before? If you don't prepare a new 64 GB stick it works, if the stick isn't new but you have never fiddled with its partition it works, and if you get to prepare it with the correct requisites it works too, but normally the latter isn't necessary. It is necessary if for whatever reason the partition isn't 32 GB or bigger.

The "31.9 GB personality" has caused some confusion. That's all the problem.

Okay, in the case of making a recovery drive, I realized this wasn't going to happen, no matter what I tried, or advice I received. I even formatted the drive in NTFS, and that really screwed things up in the drive, as I had already formatted it as a recovery drive in the utility, basically it said there was zero room on the drive, and it could not be formatted using the format Windows app. So I disconnected all my drives again, for the umpteenth time (out of caution of wiping the wrong drive). I went to Computer Management and then to Disk Management. I plugged in the USB drive which was stuck in NTFS now, and it showed a partition on the drive, and right-clicked the drive. It said I could format it as a "simple drive," and it would remove all partitions. So, I tried it, and it did open the drive up again, without partitions in NTFS.

I still wanted a bootable drive, so I followed the 1st set of instructions given on this forum to create a windows bootable installation media, posted earlier by Zbook (Thanks Zbook). I was successful. I hope I never have to use it, but like insurance, it is there.

And, thanks to Glasskuter, I will be looking into Hasleo as soon as I have a chance.

Just to set the record straight - what I wound up with was a drive formatted in - you guessed it: FAT32 (see pix)! Thanks, everyone for your help!

@archfoto
Please run Device Manager and double check all USB devices are working properly ie. no yellow exclamation marks on any of them then use a different port to plug in your USB stick.
If still does not work then the program Recovery.exe might be defective. Try to run:
dism /online /cleanup-image /restorehealth
sfc /scannow
FYI,
- To create a Recovery Drive with System Files included, you will need a USB stick with 16GB minimum. In reality it will take ~8GB+
to create which include System Files, Drivers, new .wim files etc... customized for your PC.
- The RevoveryDrive.exe program will wipe out the drive, initialize it as MBR type disk, create partition and format as FAT32 so you have no control over this.
Once done and reboot, you will get a screen as follows:

Booting the Windows Recovery from the installation Media is completely different. So you are absolutely correct.
Others might misunderstand of what you are trying to do.

P.S Personally I use backup software to backup/Restore. It is much faster and more flexible. Just do this to help you with your problem.

Topgundcp said:

@archfoto
Please run Device Manager and double check all USB devices are working properly ie. no yellow exclamation marks on any of them then use a different port to plug in your USB stick.
If still does not work then the program Recovery.exe might be defective. Try to run:
dism /online /cleanup-image /restorehealth
sfc /scannow
FYI,
- To create a Recovery Drive with System Files included, you will need a USB stick with 16GB minimum. In reality it will take ~8GB+
to create which include System Files, Drivers, new .wim files etc... customized for your PC.
- The RevoveryDrive.exe program will wipe out the drive, initialize it as MBR type disk, create partition and format as FAT32 so you have no control over this.
Once done and reboot, you will get a screen as follows:
View attachment 159088
Booting the Windows Recovery from the installation Media is completely different. So you are absolutely correct.
Others might misunderstand of what you are trying to do.

P.S Personally I use backup software to backup/Restore. It is much faster and more flexible. Just do this to help you with your problem.

Click to expand...

Thanks, Topgundcp!

archfoto said:

Thanks, Topgundcp!

Click to expand...

Topgundcp said:

@archfoto
Please run Device Manager and double check all USB devices are working properly ie. no yellow exclamation marks on any of them then use a different port to plug in your USB stick.
If still does not work then the program Recovery.exe might be defective. Try to run:
dism /online /cleanup-image /restorehealth
sfc /scannow
FYI,
- To create a Recovery Drive with System Files included, you will need a USB stick with 16GB minimum. In reality it will take ~8GB+
to create which include System Files, Drivers, new .wim files etc... customized for your PC.
- The RevoveryDrive.exe program will wipe out the drive, initialize it as MBR type disk, create partition and format as FAT32 so you have no control over this.
Once done and reboot, you will get a screen as follows:
View attachment 159088
Booting the Windows Recovery from the installation Media is completely different. So you are absolutely correct.
Others might misunderstand of what you are trying to do.

P.S Personally I use backup software to backup/Restore. It is much faster and more flexible. Just do this to help you with your problem.

Click to expand...

Hi Topgundcp -
What directory should I be in in the command prompt to run the script? Also, should that all be typed on one line? Thanks.

archfoto said:

Okay, in the case of making a recovery drive, I realized this wasn't going to happen, no matter what I tried, or advice I received. I even formatted the drive in NTFS, and that really screwed things up in the drive, as I had already formatted it as a recovery drive in the utility, basically it said there was zero room on the drive, and it could not be formatted using the format Windows app. So I disconnected all my drives again, for the umpteenth time (out of caution of wiping the wrong drive). I went to Computer Management and then to Disk Management. I plugged in the USB drive which was stuck in NTFS now, and it showed a partition on the drive, and right-clicked the drive. It said I could format it as a "simple drive," and it would remove all partitions. So, I tried it, and it did open the drive up again, without partitions in NTFS.

I still wanted a bootable drive, so I followed the 1st set of instructions given on this forum to create a windows bootable installation media, posted earlier by Zbook (Thanks Zbook). I was successful. I hope I never have to use it, but like insurance, it is there.

And, thanks to Glasskuter, I will be looking into Hasleo as soon as I have a chance.

Just to set the record straight - what I wound up with was a drive formatted in - you guessed it: FAT32 (see pix)! View attachment 159041 Thanks, everyone for your help!View attachment 159042

Click to expand...

Just to clarify. You took a 64 GB USB Flash/Thumb drive. Connected it to a computer. Launched the Disk Management, erased all the partitions that were there and then used it to create a Windows Recovery Drive (i.e. C:\Windows\System32\RecoveryDrive.exe). It was a success and now the USB Flash/Thumb drive which was 64 GB in capacity is now shown as 31.9 GB. Is this correct?