Upgrading to ESXi 4.1.x using Update Manager or the vSphere Host Update Utility fails with the following error:ERROR: Unsupported boot disk
This issue occurs when ESXi 3.5 Embedded is installed on Serial Attached SCSI (SAS) disks or Fibre Channel (FC) disks and customer is doing an in-place upgrade of ESXi. In this scenario, scratch partition is not created during the first boot of ESXi 3.5 as SAS/FC disks are considered as non-local disk, but VMFS partition is created at the location of scratch partition. The precheck script considers the scratch partition is created with a different size, therefore it returns unsupported boot disk error.
This issue is observed with HP DL380 G7 that has the Smart Array P410i controller.
See the VMware vCenter Update Manager Administration Guide for instructions on using Update Manager to download and install patches to automatically update ESX 4.1 hosts.
To update ESX 4.1 hosts when not using Update Manager, download the patch ZIP file fromhttp://support.vmware.com/selfsupport/download/ and install the bulletin using esxupdate from the command line of the host. For more information, see the ESX 4.1 Patch Management Guide.
Based on VMware KB 2013596