I have recently just done that.
Here is how.
Your flash pen drive should be in Fat16 format if it is below 2Gb as this is the standard .
You make a /boot/grub partition inside this pen drive.
You then copy the entire content of the /boot/grub from the existing Linux into the /boot/grub of the flash drive. So that you end up with /boot/grub in the flash drive with all the stage1, stage1, fat_stage_1.5, etc inside.
Activate a Grub shell, tell Grub the root is in the current Linux partition 2 and set up Grub in the pen drive's MBR.
I shall give a complete run down of the terminal commands in root with the following assumptions thinking you can adjust for your own circumstance
Say you are running a Pata disk call hda. The second partition will be call hda2. without the pen drive hda is the first bootable disk known to Grub as (hd0) and the partition hda2 will be called (hd0,1) because Grub counts everything from 0.
Now I assume you boot up the Suse Linux, plug the USB flash drive in and discover by root terminal command "fdisk -l" that the flash drive is called sda and there is only one partition sda1 inside.
Commands to get root privilege in Suse terminal
following by root password.
Commands to view every partition of every disk as seen by Linux
Commands to mount sda1 if it isn't mounted already
Code:
mount /dev/sda1 /mnt/sda1
Check Suse /media as sda1 may be mount automatically there. I assume the flash drive is in /mnr/sda1.
Command to create /boot/grub in sda1
Code:
mkdir /mnt/sda1/boot
mkdir /mnt/sda1/boot/grub
Commands to copy the content of /boot/grub from the existing Suse to /mnt/sda1
Code:
cd /boot/grub
cp * /mnt/sda1/boot
commands to setup Suse's Grub in the flash drive by a Grub shell
Code:
grub
root (hd0,1)
setup (hd1)
quit
In the above Grub is set up in the MBR of the 2nd disk (hd1) using the root partition information from (hd0,1) or hda2.
Grub will check (hd1) disk to find /boot/grub. If the necessary files are there Grub will report the operation successful. Thereafter your flash drive will be bootable with the same Grub screen as you have now.
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The bad news
When you have the flash drive plugged in to boot up the PC the Grub boot loader will be there but your systems will not boot. This is because the flash drive is now regarded by the Bios as (hd0) for being the first bootable disk. The internal hard disk becomes (hd1). The booting instructions from your hard disk assumes hda is (hd0) but now it becomes (hd1) so the booting will fail.
So to boot the two systems successfully you need to edit the /boot/grub/menu.lst in the flash drive to change all "hd0" to "hd1".
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Last word--------------
Suse uses gfxmenu which can rob you the ability to boot the systems "manually". I recommend you to edit the Suse's /boot/grub/menu.lst to put a "#" in front of the line starting with fgxmenu. The "#" will disable the line temporarily and removing it will get you back the original menu. Without gfxmenu you can press "c" at the Grub screen to get a Grub prompt.
In a Grub prompt there is no PC system that Grub cannot boot! but you have to do it manually.
Hope this helps