I receive a RDISK error, disk is full.

A. A. When you run the rdisk.exe it updates the directory %systemroot%repair with the following files

As the system is used the files setup.log, sam._ and security._ will grow. The sam._ and security._ files are only updated if rdisk.exe is run with /s qualifier, e.g. rdisk /s.

If the contents of the %systemroot%repair directory exceeds 1.44 MB then you will receive the error "The Emergency Repair disk is full. The configuration files were saved in your hard disk". You should look at the contents of the repair directory and ascertain which file is the problem, i.e. setup.log is 1MB!

If setup.log if the problem then you can perform the following.

If the problem is not setup.log and is that the sam._ and security._ files are too large then the problem is there are too many accounts on the system so you need to delete some of your user accounts :-) Only joking!

What you can do is locate an ERD that was created early in the computers life where the sam._ and security._ files are small and copy these to the %systemroot%repair directory and in future do not run rdisk.exe with /s option. This does mean that account information will not be recoverable and you will need to know what the Administrator password was when the original ERD was created (as if it was used accounts would be set back to this state).

Obviously you will still want to be able to restore accounts in the event of a disaster so I would suggest one of the following

For more information see Knowledge base article Q130029 at http://support.microsoft.com/support/kb/articles/q130/0/29.asp