[lintweaker]

Did you perhaps skip the dvhtool commands (after 'cd /stand') as described in the cloning guide you mentioned in the first post? The I/O error might be related to missing file(s) in the volume header.

If you did install the correct files to the volume header, then the error could also indicate a hardware problem with that area of the disk.

It was an issue with the clone disk. I put in another disk to use as clone disk. This one booted up just fine.
The original clone disk happily took all files only the volume header was troublesome. Luckily I have plenty of spare disks lying around.