I mean VERY strange, and you'll find out why in a minute. First of all, let me just say that I've narrowed this down to the Wii side, having tested multiple USB drives formatted in both FAT32 and NTFS to exactly the same results.
On my launch day, Wiikey-1-chipped, 4.2E console, I had a 2 year old working setup of HBC 1.0.8 (later 1.1.0) running on IOS61, cIOSX r20b, and CFG USB loader. Recently, for no apparent reason, HBC started refusing to boot with the HDD plugged in. If I remove the HDD, it runs. After having ruled out HDD problems, HBC updates and file system issues, I decided to toy around with IOS's, even though my previous setup worked fine. The results were as follows:
HBC running on IOS 58 - runs fine without HDD, black screen with it.
IOS 61 - same as above, but unplugging the HDD on the fly gets it to boot.
On both, using the HDD on port 1 instead of 0 makes it run fine.
After getting it to run using port 1, I tried CFG loader. This is where it gets strange: with most cIOSs, it just refuses to recognise anything connected to port 1. When I use a cIOS based on IOS 58, it loads everything perfectly, and games work! However, and here comes the dealbreaker, they run at USB 1.1 speed. As you may be able to imagine, this is painfully slow.
Given all of this, I'm leaning towards a damaged port 0, which sucks big time. Any ideas?
This is going to sound crazy since the cable works when you connect it to the PC, but your symptoms are incredibly familiar to me. What you need is a new USB cable if that's an option with your enclosure. Yes, it was that simple in my case. I have no idea why, but the USB cable that came with my drive worked perfectly fine with PC but just refused to work with the Wii - USB Loaders would detect the drive but then fail to load or wouldn't detect the drive at all until I changed the cable which worked like a charm for whatever reason - must've been interference or something on the cable itself.
If that does not help, I strongly suggest downloading ModMii and running a complete re-mod of your Wii, preferably still on 4.2 because it's easily vulnerable and updating to 4.3 gives no benefits.
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Quoting: Comment on: Strange USB HDD behaviour. Help!