How to transfer your old bigger HDD to smaller SSD without Windows 10 reinstall

My scenario

Move all data from old 500GB HDD HP 250 g3 notebook (year 2014) to the new SSD disk WD 240GB. Important notice: there has been 400GB of unused space on the 500GB old HDD! So I need to copy only 100GB of files to 240GB SSD.

Problems

old HDD is bigger than new one
bad sectors on old HDD
need correct software to migrate and shrink big partitions to smaller sizes

AOMEI Partition Assistant - Bad corrupted HDD sector, on that all copy programs failed to transfer data

Hardware needed

another Notebook with Windows 10
at least one external USB BOX (in my case I needed USB 2.0 BOX from Kingston because USB 3.0 from ORICO disconnects disk when tried to copy from bad sector)
some external USB flash disk 1GB+ for Recovery boot
extra external USB flash disk for create Bootable disk if you use tools like EASYUS Disk Copy Pro

Kingston USB 2.0 external HDD box vs Orico USB 3.0

EASEUS Disk Copy Pro - Create Bootable Disk

Create USB Recovery Drive (optional)

if your computer could not boot, use another computer and create Recovery USB flash disk. You will need this later, if your new SSD will not boot
insert your empty external USB flash disk to your working computer with Windows 10
open start menu and type: "create recovery drive" and open app
uncheck "backup system files" and click next
select your empty USB flash disk - all data on this flash disk will be deleted!!
click next
when finished, you can use this flash drive and boot from it and repair you computer from CMD console

open start menu and type: "create recovery drive" and open app

select your empty USB flash disk - all data on this flash disk will be deleted!!

Copy all data from old HDD to new SSD disk

In my scenarion I need to use EASEUS Disk Copy Pro software, because I need to move data from bigger disk to smaller one (500GB HDD -> 240GB SSD).

If your old HDD have bad sectors try to use external USB 2.0 HDD Box

Create Bootable Disk with EaseUS Disk Copy Pro and run this tool from USB Flash disk
Insert old HDD to USB 2.0 External BOX
Insert new SDD into your notebook or in another external USB BOX
Copy all data to new SDD disk

Unable to boot from new SDD

Now you have new SDD disk with all your data from old HDD but your computer will end on blue screen, with error message, that your computer could not boot.

use your Windows Recovery Flash disk from optional step (not your Bootable disk from EaseUS Disk Copy Pro!!)
start computer enter into bios
in boot section disable secure boot!!
setup boot sequence to boot firstly from external USB (your Recovery USB disk). You can try to press Enter when computer starts and select F12 to select booting from. Some computers have F8.
boot from Recovery disk, select you keyboard type if you will be asked
select Troubleshoot and Command Prompt

Windows Recovery Troubleshoot

Windows Recovery Command Prompt

Run Diskpart and check you disk layout

in the Command Prompt run diskpart
list disk
sel disk 0
list vol
// find FAT32 volume (e.g. number 3) and assing letter if not assigned
sel vol 5
assign letter=l:
list part
// find recovery partition number (e.g. 5) and write this part number on the paper
exit

diskpart

Repair path to your system Recovery

reagentc /info
reagentc /setreimage /path \?\GLOBALROOT\device\harddisk0\partition5\Recovery\WindowsRE /target C:\Windows
// where harddisk0 is my hdd index (in my example 0, harddisk1 ... in your? run diskpart again and list disk and check this)
// where partition5 is my part number from diskpart from Recovery partition

Windows Recovery partition - reagentc

Repair BCD boot table

Note: disk C is where is your main Windows folder located. disk L is your FAT32 drive that you assigned via diskpart via assign letter=l:

disconnect your Recovery Flash Disk! Otherwise boot will be corrupted via param ALL in next commands
bcdboot c:\Windows /s L: /f ALL
bootsect /nt60 ALL /force
bootrec /fixboot
bootrec /rebuildbcd

Done

Other resources for advanced users