Check if there is an entry for /dev/sda1 in your /etc/fstab file. If so, and it was entered manually, then you need to boot up into the rescue system and comment out the line.
By entered manually, I mean it starts like '/dev/sda1 /<mountpoint> vfat'
If it looks like:
'usbfs /proc/bus/usb usbfs noauto 0 0
'
then the problem is elsewhere. Another option if the first case is true is to use the 'noauto' option, so an attempt isn't made to mount it during the boot process. This way, after inserting it, you can manually mount it (assuming the hotplug system doesn't mount it for you)
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