STR: 1. Go to https://treeherder.mozilla.org/#/jobs?repo=mozilla-central&revision=89167fe9d3ba 2. Click on the Flame-KK(Be) link under "B2G Device Image opt" 3. Click on "Inspect Task" in the bottom pane that shows up (You may need some permissions fiddled with to access the TaskCluster artifacts) 4. Under the Artifacts, download "private/build/flame-kk.zip" 5. Unzip the zipfile from step 4 6. Plug in a Flame and ./flash.sh it Output: kats@kgupta-air b2g-distro$ ./flash.sh < waiting for device > ******** Did you mean to fastboot format this partition? erasing 'cache'... OKAY [ 0.078s] finished. total time: 0.078s ******** Did you mean to fastboot format this partition? erasing 'userdata'... OKAY [ 1.011s] finished. total time: 1.011s target reported max download size of 301989888 bytes erasing 'userdata'... OKAY [ 0.959s] sending 'userdata' (36916 KB)... OKAY [ 1.161s] writing 'userdata'... OKAY [ 1.413s] finished. total time: 3.533s target reported max download size of 301989888 bytes erasing 'cache'... OKAY [ 0.061s] sending 'cache' (5304 KB)... OKAY [ 0.169s] writing 'cache'... OKAY [ 0.207s] finished. total time: 0.436s target reported max download size of 301989888 bytes sending 'boot' (7486 KB)... OKAY [ 0.236s] writing 'boot'... OKAY [ 0.280s] finished. total time: 0.516s target reported max download size of 301989888 bytes erasing 'system'... OKAY [ 0.493s] sending sparse 'system' (294851 KB)... OKAY [ 9.464s] writing 'system'... FAILED (remote: size too large) finished. total time: 9.959s Flashing out/target/product/flame/system.img failed because the image was too large. Try re-flashing after running $ rm -rf out/target/product/flame/data && ./build.sh

Same thing happens on my local flame-kk build.

I have a prebuilt flame-kk.zip from circa july 6 and that flashes fine, so I'm gonna say this is a regression.

You need to have proper partition table. Confere the notes there: https://developer.mozilla.org/en-US/Firefox_OS/Phone_guide/Flame/Updating_your_Flame#Updating_your_Flame_to_a_nightly_build

Thanks for the link; updating my base image fixes the issue.