I have a 5 disk raid that is currently using only 4 disks. On startup, it rejects an apparently good drive with the message that it is non-fresh. I don;t understand what non-fresh means nor how to resolve this. I start the raid using the command: oak:~# mdadm -A /dev/md0 -f /dev/sd[abcd]1 /dev/hd[eg]1 mdadm: /dev/md0 has been started with 4 drives (out of 5). and I see: oak:~# cat /proc/mdstat Personalities : [raid5] md0 : active raid5 sdb1[1] hde1[4] sdd1[3] sdc1[2] 781433344 blocks level 5, 32k chunk, algorithm 2 [5/4] [_UUUU] unused devices: <none> (It does not start automatically and at the moment, /dev/hdg1 is not installed, but at the time that /dev/hdg1 failed, this command worked and had all 5 drives working.) dmesg reports: md: md0 stopped. md: unbind<hde1> md: export_rdev(hde1) md: bind<sda1> md: bind<sdc1> md: bind<sdd1> md: bind<hde1> md: bind<sdb1> md: kicking non-fresh sda1 from array! md: unbind<sda1> md: export_rdev(sda1) raid5: measuring checksumming speed 8regs : 1072.000 MB/sec 8regs_prefetch: 1012.000 MB/sec 32regs : 784.000 MB/sec 32regs_prefetch: 732.000 MB/sec pII_mmx : 2172.000 MB/sec p5_mmx : 2888.000 MB/sec raid5: using function: p5_mmx (2888.000 MB/sec) md: raid5 personality registered as nr 4 raid5: device sdb1 operational as raid disk 1 raid5: device hde1 operational as raid disk 4 raid5: device sdd1 operational as raid disk 3 raid5: device sdc1 operational as raid disk 2 raid5: allocated 5242kB for md0 raid5: raid level 5 set md0 active with 4 out of 5 devices, algorithm 2 RAID5 conf printout: --- rd:5 wd:4 fd:1 disk 1, o:1, dev:sdb1 disk 2, o:1, dev:sdc1 disk 3, o:1, dev:sdd1 disk 4, o:1, dev:hde1 I see no indication of a problem with /dev/sda1. I can open it with fdisk and it seems to report the correct partition table: oak:~# echo p |fdisk /dev/sda The number of cylinders for this disk is set to 24321. There is nothing wrong with that, but this is larger than 1024, and could in certain setups cause problems with: 1) software that runs at boot time (e.g., old versions of LILO) 2) booting and partitioning software from other OSs (e.g., DOS FDISK, OS/2 FDISK) Command (m for help): Disk /dev/sda: 200.0 GB, 200049647616 bytes 255 heads, 63 sectors/track, 24321 cylinders Units = cylinders of 16065 * 512 = 8225280 bytes Device Boot Start End Blocks Id System /dev/sda1 1 24321 195358401 fd Linux raid autodetect Command (m for help): Command (m for help): Command (m for help): got EOF thrice - exiting.. oak:~# and I can 'dd' from /dev/sda1 without any reported errors. looking back in the logs, the only thing I find is: Sep 21 21:20:10 localhost -- MARK -- Sep 21 21:40:10 localhost -- MARK -- Sep 21 21:46:22 localhost kernel: device-mapper: device /dev/sda1 too small for target Sep 21 21:46:22 localhost kernel: device-mapper: error adding target to table Sep 21 21:46:22 localhost kernel: device-mapper: device /dev/sda1 too small for target Sep 21 21:46:22 localhost kernel: device-mapper: error adding target to table Sep 21 21:47:30 localhost kernel: device-mapper: device /dev/sda1 too small for target Sep 21 21:47:30 localhost kernel: device-mapper: error adding target to table Sep 21 21:47:30 localhost kernel: device-mapper: device /dev/sda1 too small for target Sep 21 21:47:30 localhost kernel: device-mapper: error adding target to table Sep 21 21:47:47 localhost kernel: ReiserFS: dm-0: warning: sh-2021: reiserfs_fill_super: can not find reiserfs on dm-0 Sep 21 21:49:02 localhost kernel: md: md0 stopped. Sep 21 21:49:02 localhost kernel: md: unbind<hde1> Sep 21 21:49:02 localhost kernel: md: export_rdev(hde1) Sep 21 21:49:03 localhost kernel: md: bind<sdb1> Sep 21 21:49:03 localhost kernel: md: bind<sdc1> Sep 21 21:49:03 localhost kernel: md: bind<sdd1> Sep 21 21:49:03 localhost kernel: md: bind<hde1> Sep 21 21:49:03 localhost kernel: md: md_import_device returned -16 Sep 21 21:49:03 localhost kernel: raid5: measuring checksumming speed Sep 21 21:49:03 localhost kernel: 8regs : 1072.000 MB/sec Sep 21 21:49:03 localhost kernel: 8regs_prefetch: 1012.000 MB/sec Sep 21 21:49:03 localhost kernel: 32regs : 784.000 MB/sec Sep 21 21:49:03 localhost kernel: 32regs_prefetch: 732.000 MB/sec Sep 21 21:49:03 localhost kernel: pII_mmx : 2168.000 MB/sec Sep 21 21:49:03 localhost kernel: p5_mmx : 2892.000 MB/sec Sep 21 21:49:03 localhost kernel: raid5: using function: p5_mmx (2892.000 MB/sec) Sep 21 21:49:03 localhost kernel: md: raid5 personality registered as nr 4 Sep 21 21:49:03 localhost kernel: raid5: device hde1 operational as raid disk 4 Sep 21 21:49:03 localhost kernel: raid5: device sdd1 operational as raid disk 3 Sep 21 21:49:03 localhost kernel: raid5: device sdc1 operational as raid disk 2 Sep 21 21:49:03 localhost kernel: raid5: device sdb1 operational as raid disk 1 Sep 21 21:49:03 localhost kernel: raid5: allocated 5242kB for md0 Sep 21 21:49:03 localhost kernel: RAID5 conf printout: Sep 21 21:49:03 localhost kernel: --- rd:5 wd:4 fd:1 Sep 21 21:49:03 localhost kernel: disk 1, o:1, dev:sdb1 Sep 21 21:49:03 localhost kernel: disk 2, o:1, dev:sdc1 Sep 21 21:49:03 localhost kernel: disk 3, o:1, dev:sdd1 Sep 21 21:49:03 localhost kernel: disk 4, o:1, dev:hde1 This happened when I was starting up md and lvm and perhaps I tried to start lvm before starting the raid. Could the device-mapper have written something to the partition that has caused md (mdadm?) to reject it? My inclination is to delete and recreate the partition on the device and try again, but I thought I'd ask here first since I don;t understand how I got into this situation in the first place. thanks, hank -- Beautiful Sunny Winfield, Illinois - To unsubscribe from this list: send the line "unsubscribe linux-raid" in the body of a message to majordomo@xxxxxxxxxxxxxxx More majordomo info at http://vger.kernel.org/majordomo-info.html