Brand new nano, will not sync, still says do not disconnect

I have a brand new nano that does not seem to want to sync with my itunes. Each time I plug it in it asks me to name the iPod, which I do, then it says updating, do not disconnect. So once itunes is done updating the nano still says do not disconnect. So everytime I have to eject it properly and it never updates with the information from my itunes. It also has a bunch of orange space that it says is being used on the capacity bar and there is no information on the iPod. I have restored it back to factory settings and no luck... I have also taken it in to the Apple Genius Bar and they said it wad fixed and it wasn't so then they gave me a new one and it has the same problem...HELP!
iPod Nano 2 GB Windows XP Pro

here is a link to more detail on jeff's suggestion
http://docs.info.apple.com/article.html?artnum=93499
KoDor
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Boot from the Install Disk 1
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Brand new nano, will not sync, still says do not disconnect

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