1) Format the US Drive with fat32.
2) Get Syslinux, not the version 4, but an older version. Use 3.86 from http://www.kernel.org/pub/linux/utils/boot/syslinux/3.xx/
Version 4 can give you an error on boot, "invalid c32 image".
3) Run syslinux: syslinux.exe -m -f -a G: (G: being the drive letter).
4) Get the ESXi iso, VMware-VMvisor-Installer-4.1.0.update1-348481.x86_64.iso
5) Extract the iso, using the 7-Zip and copy contents to usb drive
6) Rename isolinux.cfg to syslinux.cfg
7) Modify the syslinux.cfg, add "ks=usb" after vmkboot.gz
For example ,
append vmkboot.gz ks=usb --- vmkernel.gz --- sys.vgz --- cim.vgz --- ienviron.vgz --- install.vgz
8) Create the ks.cfg file in the USB root directory with the following contents
vmaccepteula
rootpw Welcome1
autopart --firstdisk --overwritevmfs
install usb
network --bootproto=dhcp --device=vmnic0
9) Boot it from the USB and install the ESXi software
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