KR1 Firmware Upgrade Problems - To Bix or Not to Bix?

Scott · Last edited by Scott on Tue May 09, 2006 6:42 pm; edited 3 times in total

Some users have experienced repeated problems attempting to upload newer firmware to their KR1. They end up stuck at the recovery page after each reboot and are met with a common error when attempting to upload the firmware file again: "Wrong Image File is Selected". We have seen this error (on both OS X and Windows with all browsers, in fact) ... yet attempting another firmware update has worked in many instances.

So far in a number of cases we have been shipped "dead" or "bricked" KR1's only to bring them "back to life" after one to three upload attempts. As I have personally walked users through recovery attempts, I know they are following every step correctly.

We want users to be aware of the issue. Maybe if you don't need the update, don't do the update. We will hopefully find out what the problem is.

One question that keeps coming up (that I can't answer): is it related to the file type, aka .bix, or how browsers/systems treat that type of file (formatting, etc.), or is it something else entirely?

tz1 · Posted: Tue Apr 04, 2006 1:47 pm Post subject:

For me, Firefox seems to work for an update - if it is successful (and I wait the 10 minutes before the manual reboot, or I'm logged in so I can tell when it is done).

The recovery mode seems to require Internet Explorer (I'm using some version 5), and it will abort, but you also need the 10 minutes waiting even if it seems like it failed (without the message).

The file ending doesn't seem to be a problem for me, and it is an upload.

(Theoretically, if the file was the wrong type or otherwise corrupted, you should have gotten the message from the main firmware update).

Also blame DLink for requiring a multipart base-64 encoded upload instead of doing an FTP server or something else where binary transparency could be done more easily. They've left TFTP open, but there is no instruction as to how to use it for flash.

Scott · Posted: Tue Apr 04, 2006 3:33 pm Post subject:

tz1 · Posted: Tue Apr 04, 2006 7:07 pm Post subject:

Actually, you can simply do "tftp 192.168.0.1 / binary / put run.bix" and it will start flashing and it will flash, but won't work (it will brick).

Mackieman · EVDO Junkie Joined: 31 Oct 2005 Posts: 471

I need more information to look into this problem deeper. I've had a couple of units experience a bad flash but brought it back using the method we all know but can't talk about. In mass flashing of several hundred units only a couple of failures were noted. I'm really wondering if a lot of the issue isn't user error in not letting it go long enough before they powercycle it or closing the browser before the cycle is completed.

tz1 · Posted: Thu Apr 13, 2006 4:24 pm Post subject:

I suspect the problem is not letting the flash complete.

There is almost no way to tell (without hacked firmware), which is why I say wait 10 minutes. They don't stop flashing the status light or anything else. (complain to DLink or have them release the code they are supposed to under GPL so I can do so).

Technically you won't get a web page or even an IP address back until it is done, so you can pull the hardwire ethernet cable after about a minute, then reinsert it.

When you can get any KR1 web page again, the flash has completed but you aren't running the updated software yet unless you cycle power.

The unbrick function seems to reset by itself when it is done flashing.

Mackieman · EVDO Junkie Joined: 31 Oct 2005 Posts: 471

Nearly every time I flash the firmware (which I do often in testing) and follow the instructions the router recovers as it should. I've used Firefox, IE, and Safari with no issues. I'm still leaning toward this issue being mostly user error but I need more information to investigate further.

tz1 · Posted: Mon Apr 17, 2006 1:19 pm Post subject:

I've never had my KR1 reboot by itself from normal flashing. Usually the HTTP session times out, but after it is done I can hit refresh or just go to the home page, but need to force a reset for it to see the new firmware.

But during flashing, the KR1 appears dead, except to pings, and if there are established sessions they will still work. Sometimes I can telnet into it, but it is spotty (the flash has webs take up 98%+ of the CPU).

Scott · Posted: Mon Apr 17, 2006 6:51 pm Post subject:

I've had them always reboot after 'recovery' re-flashing, except for maybe the first time I upgrade one from RK1001. But then I know to wait.

After I am running RK1002 then that's the only thing I have ever seen happen. I've reloaded one of them here over and over trying to *get* failure. None yet: it reboots, browser refreshes and I'm staring at the Firmware upload page, just like I should.

This happens with a Fully updated WinXP box using the newest Firefox 1.5.0.2 and current Internet Explorer, or on Mac OS 10.4.5 (and .6) using Firefox, Safari, or Camino.

Michael has had a number come back as 'bricks' and after one (or a couple) re-flashing(s) they're back, fully functional. In a particular case I worked with one fellow who diligently tried everything I suggested. He downloaded the firmware numerous times from multiple places. He was waiting out the ten minutes, or so he indicated, yet still nothing. Michael gets it, hits it with a recovery attempt and TADA! Working router.

We have yet to duplicate the 'failure'. ?

Michael · Posted: Mon Apr 17, 2006 7:13 pm Post subject:

I have seen the "Wrong Image" message many times. I hit the back button, try again and sometimes it takes a few tries and before it recognizes the image.

Scott another "interesting" idea would be to enable the admin over the web and do the firmware upgrades remotely. This sounds cool BUT dangerous.

We have seen some KR1s that couldn't be recovered, but those quantities are very low.
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tz1 · Posted: Mon Apr 17, 2006 9:27 pm Post subject:

With 1002, do you see it reboot, or does it refresh? My browser will not refresh (but I have enough FFox extensions and settings it might not work), but the KR1 comes back after a flash WITHOUT rebooting. I'm watching it and if I'm running my firmware I have a telnet session, but the webs program is the same for both.

I have one of the first run models and it is possible it also has a different loader that might make the reboot problematic. Want to trade (if only for curiosity)? Mine works but has a few bruises from dropping out of my bag on the way to the car.

Scott · Posted: Mon Apr 17, 2006 10:06 pm Post subject:

After five minutes (literally), I see a center-justified message indicating that the router is rebooting: "The device is restarting. Please wait for XX seconds", where the XX is actively counting down. After the count-down the browser automatically refreshes and then I'm back at the Firmware Upgrade page which indicates the current firmware version and date.

Mackieman · EVDO Junkie Joined: 31 Oct 2005 Posts: 471

Scott sees exactly what I do. After a firmware flash the entire router does a soft reboot. That countdown page is what displays after the flash is loaded.

Scott · Posted: Tue Apr 18, 2006 11:33 am Post subject:

I took that grab last night after a 'standard' reload on a working router. Did it with Firefox 1.5.0.1 on Mac OS 10.4.6., just to double-check Apple boxen (vs the three Win2K/WinXP machines here in my office). Works the same with Safari and Camino. Haven't tried it with Linux... hmmm...

tz1 · Posted: Tue Apr 18, 2006 12:07 pm Post subject:

I've never seen that screen, and I'm using the latest version of Firefox.