I would suggest first backing up the system.

Make sure you have a copy of tar at /bin/tar.
mv /usr /oldusr (as root, of course)
Launch mcc (you may have to use full path name /oldusr/bin/mcc), to
local disks, to manage local disks. Create a new partition and name
it usr, mount it on /usr. Quit mcc and cd /usr. Make sure you are
in an empty directory of correct size, i.e. that your changes took
effect. cd /usr ; df -k . (period is part of the command)
Then, as root (to keep ownership/group/permissions/etc)
(cd /oldusr ; tar -cf - . ) | (cd /usr ; tar -xf - )
dd and rsync should also be usable for this,
as is cp -pR /oldusr/* /usr. I am not sure if cp with -pR
handles symbolic links correctly, so man cp. Note that rsync
is normally /usr/bin/rsync, so you may need to use the complete
pathname /oldusr/bin/rsync if you go that route.
Do an ls -laR /usr |less to examine owner/group/permissions of
at least some of the executables in /usr/bin, to make sure all
transferred properly.
cd /etc and using vi or any other ASCII editor create a line
in fstab that matches the way in which you created/named the
partition. It might look something like one of the three
lines here:
/dev/sda6 /usr ext3 defaults,noatime 1 2
LABEL=usr /usr ext3 defaults,noatime 1 2
UUID=f3ca97a8-cbd9-4599-bf65-041b209b7ba7 /usr ext3 noatime 1 2
blkid /dev/sda6
will show you the attributes of /dev/sda6 above, to make sure the
system thinks you have named things as you intended to name them.
As an alternative on naming the partition, you could name the
new partition nusr and mount it as /nusr. Then, after moving all
the stuff under /usr under /nusr, rm =rf /usr followed by
ln -s /nusr /usr.
In closing, I would watch for better directions from BitTwister,
Dave Hodgins, or some of the other sysadmin folk who actually do
this sort of thing now and then. I do it so rarely that I might
overlook or leave out something. But, the above says what you want
to do is possible, and offers a few ways to do it.
Cheers!
jim b.
--
UNIX is not user unfriendly; it merely
expects users to be computer-friendly.