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Unexpected I/O Error
By  Super Admin  | Published  11/23/2006 | Windows XP Troubleshooting | Unrated
Unexpected I/O Error
When you try to create an MS-DOS startup disk, you may receive the following error message: An unexpected I/O error has occurred. This issue can occur if you try to create an MS-DOS startup disk with an unformatted floppy disk.

Details: http://support.microsoft.com/kb/311385/en-us?spid=1173&sid=global
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