Disk Utility error when restoring a drive to another drive: Error 6

"Device not configured."
I have a 24" iMac with a 250gig hard drive, and a firewire enclosure with a 160 gig hard drive. The iMac has a windows partition that I am trying to back up on the firewire drive, so that I can repartition and make the windows section bigger, but I keep getting errors when trying to restore.
If I uncheck erase destination, and then click restore, it starts to copy for a few minutes, but after 2-3 gigs of copying I get another error:
"Restore Failure An error (2) occurred while copying. No such file or directory"
This happens again and again and again and again. Any ideas?

Thanks for the different responses. Just a few more details. My internal hd is only using 63 of 100g.
So I don't think the disk space issue for disk utility would be the answer to my particular problem. I have also tried using superduper to back up this same drive; however, it would not complete the task either. Would it be better to just back up the user folders separately and maybe the applications folder and then just use the mac os dvd's to install on my new drive? ( I don't guess backing up the applications folder would do any good; they would have to all be reinstalled. ) Just trying to find a way to get this done without having to do to much reinstall work. Any other ideas?

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1. Drive Bay 1 contains the original 250 GB Startupdisk. It works without errors.
2. Drive Bays 3 and 4 contain each a WD Caviar Black 2 TB SATA 3 HDD. They work without errors.
3. I have purchased a third WD Caviar Black 2 TB HDD.
4. In Drive Bay 2 there has been a Seagate 750 GB HDD, which worked in conjunction with all the other drives without error.
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7. On trying to initialize the new drive with disk utility it reports the error [translated from German] "Erasing of the volume has failed. The device could not be opened."
8. I thought that the drive is faulty. Thus I created an RMA-Case at WD. They exchanged the drive without problems.
9. On getting the exchanged WD Caviar Black 2 TB drive I put it in Drive Bay 2 as before.
10. On trying to erase and format the exchange drive I got the same error message "Drive could not be opened."
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10.1 On leaving that drive selected in the devices list and clicking the info-button, disk utility will also report additional information as usual, e. g. Name, Type, partition scheme, media-identification, media name, media type, device tree, … , number of relocated sectors, etc.. All this information appears to be valid, as can be compared to the other devices information inside the other Drive Bays. Also the disk numbering scheme appears to be standard - 4 HDDs give the numbering disk0, disk1, disk2, disk3.
10.2 From that information I conclude that the SATA-bus and connectors electrically work properly, the drive has spun up and can be accessed by the system normally.
11. I powered down the computer, took out the HDDs from Drive Bays 3 and 4 and put the caddy with the new exchange drive in Drive Bay 4 [Maybe, I could have also just left it alone in Drive Bay 2, or 3].
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13. After disk utility finished formatting, I put back the original drives into Drive Bay 3 and 4 and put the now newly formatted drive back into Drive Bay 2.
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Disk Utility error when restoring a drive to another drive: Error 6

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