Don't use DD mode to create bootable USB. Use rufus and choose recommended ISO mode.

Your one of the partition of USB is unallocated and hidden. The one which is reported to have low disk space is the 3rd partition of your USB whose volume size is already in few Kilobytes which consists of efi binaries. That's why i don't like this DD mode. It does weird things with your USB.

If you go to Windows Disk Management or Gparted, you can see all 3 partitions of your USB. That's not the problem with kali. It depends which tool do you use for creating bootable USB.

Offensive secure releases ISO hybrid images of kali-linux so that you can choose either DD mode or ISO mode to make bootable USB.

Can you reproduce the problem if you create the USB disk like documented in the Kali Linux Revealed book ?

https://kali.training/chapter-2/downloading-kali-linux/

If not, then it's not our problem.

https://kali.training/chapter-2/downloading-kali-linux/

Creating a Bootable Kali USB Drive on Linux

Creating a bootable Kali Linux USB key in a Linux environment is easy. The GNOME desktop environment, which is installed by default in many Linux distributions, comes with a Disks utility (in the gnome-disk-utility package, which is already installed in the stock Kali image)...

I ALWAYS use the Disks utility to create the USB disk.
So YES it is REPRODUCIBLE.

These have the Low Disk Space on "Kali Live" problem:
kali-linux-rolling-amd64.iso
kali-linux-mate-rolling-amd64.iso

These do NOT have the Low Disk Space on "Kali Live" problem:
kali-linux-2017.1-amd64.iso
kali-linux-light-2017-W35-amd64.iso
kali-linux-xfce-rolling-amd64.iso

I will test more if you like.

@broomdodger You should at least upload a screenshot of what is taking up your entire disk space and in how many partitions your USB is divided after making it bootable in DD mode?

So it's not reproducible with images that we (Kali) ship. Are kali-linux-rolling-amd64.iso and kali-linux-mate-rolling-amd64.iso images that you built yourself ? What version of live-build did you use ?

This is reproducible with the images you ship - I've just done so with kali-linux-2017-W35-amd64.iso

dd'ing kali-linux-2017-W35-amd64.iso onto a USB stick and booting that, /dev/sdb2 (the FAT partition with \efi\boot\boot{x64,ia32}.efi) gets mounted to "/media/root/Kali Live", and then an alert notification pops up that there's only 26.6kB free on that filesystem.

@rhertzog
'Low Disk Space on "Kali Live"' dialog
is REPRODUCIBLE with images Kali ships.

I am NOT building the isos.
I download isos from Kali
then use 'Disks' to create bootable USB.

.......1.........2.........3.........4.........5.........6....

These give the 'Low Disk Space on "Kali Live"' dialog:
kali-linux-2017-W35-amd64.iso
kali-linux-2017-W35-i386.iso
kali-linux-mate-2017-W35-amd64.iso
kali-linux-mate-rolling-amd64.iso (kali daily 20170829)
kali-linux-mate-rolling-amd64.iso (kali daily 20170830)
kali-linux-rolling-amd64.iso (kali daily 20170829)
kali-linux-rolling-amd64.iso (kali daily 20170830)
kali-linux-rolling-i386.iso (kali daily 20170830)

.......1.........2.........3.........4.........5.........6....

These do NOT give the 'Low Disk Space on "Kali Live"' dialog:
kali-linux-2017.1-amd64.iso
kali-linux-mate-2017.1-amd64.iso
kali-linux-xfce-2017.1-amd64.iso
kali-linux-light-2017-W35-amd64.iso
kali-linux-light-2017-W35-i386.iso
kali-linux-xfce-2017-W35-amd64.iso
kali-linux-xfce-rolling-amd64.iso (kali daily 20170829)
kali-linux-xfce-rolling-amd64.iso (kali daily 20170830)

.......1.........2.........3.........4.........5.........6....

@broomdodger So what is that that taking up your disk space?

I get a similar notification - "Low Disk Space on ‘Kali Live’.” flash drive. (19.6gb free)

(kali-linux-2017-W33-amd64.iso)

Thanks.

@defalt Apology if I was un-clear

• I download ISOs from Kali daily, Kali weekly, and Kali release

• create bootable USB flash with gnome-disk-utility as per Kali_Revealed_1st_edition.pdf

• boot fresh from the USB flash

• 'Low Disk Space on "Kali Live"' dialog is displayed

Here is a screenshot of mine. (And yes, I realize that it's not referring to the 'persistence' partition.)

Thanks.

I also have this same problem. I downloaded the Kali Linux Mate W37 iso file. I then followed the instructions from https://kali.training/chapter-2/downloading-kali-linux/ using both the Gnome Disks on Linux method and the command line on Linux method to write to USB. I also added persistence by creating a third partition and labeling it as "persistence" and following the persistence guide https://docs.kali.org/downloading/kali-linux-live-usb-persistence.

On my first boot of the newly created Kali Live USB stick, selected persistence mode and received the low disk warning. I hadn't touched anything as this was my first boot, hadn't even moved the mouse. I have attached a picture for reference.

In case it helps here is the output of "fdisk -l" command that I ran on Kali Live:
Disk /dev/sdb: 29.9 GiB, 32078036992 bytes, 62652416 sectors
Units: sectors of 1 * 512 = 512 bytes
Sector size (logical/physical): 512 bytes / 512 bytes
I/O size (minimum/optimal): 512 bytes / 512 bytes
Disklabel type: dos
Disk identifier: 0xaa612877

Device     Boot   Start      End  Sectors  Size Id Type
/dev/sdb1  *         64  5815615  5815552  2.8G 17 Hidden HPFS/NTFS
/dev/sdb2       5815616  5817023     1408  704K  1 FAT12
/dev/sdb3       5818368 62652415 56834048 27.1G 83 Linux

Kali is pointing low disk space to the FAT12 700KB partition of your USB in which your efi files are present to boot USB.

Hello,

I have the same problem with kali-linux-2017.2-amd64.iso

I used dd to make a bootable USB

As of today (having triple and quadruple checked), am NO LONGER getting a "Low Disk Space on ‘Kali Live’” alert. I'm not sure if any updating rectified the issue.

Thanks.

http://archive.kali.org/kali-daily-images/
kali-linux-rolling-amd64.iso 11-Oct-2017 01:50 2824994816
kali-linux-mate-rolling-amd64.iso 11-Oct-2017 05:29 2772140032

NO MORE 'Low Disk Space on "Kali Live"' alert
with either gnome or mate
they seem fixed

What fixed them?

Nice to hear that, it's probably the upgrade of gnome-disk-utility to 3.26.0 or 3.26.1 that fixed this.

https://pkg.kali.org/pkg/gnome-disk-utility