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Here is the complete tutorial on how to create a working OS on your USB.

Damn Small Linux USB install tutorial:

1. Download the HP-USB Format tool and format your flash drive using the Fat or Fat32 option
2. Download the dsl-embedded.zip and extract the contents using 7-Zip to your “USB flash drive”
3. Download syslinux-3.36.zip and unzip the files to a directory called syslinux on your computer
4. From Windows click start-> run-> cmd
5. From the command window, type cd \syslinux\win32
6. Type syslinux.exe -ma X: (replace X with your USB drive letter) to make the drive bootable
7. Reboot your computer and set your system BIOS or Boot Menu to boot from the USB device. In some cases, you might also need to set the hard disk boot priority to boot from the USB stick if your BIOS lists the device as a hard drive.

Notes: It is possible to “boot DSL using Qemu emulation” without the need to reboot the PC. See the included readme file that was written by the authors of DSL.

If you still can’t get DSL to work, you can try this full installation tutorial direct from the DSL wiki