IPod Classic Frequent restore errors

Hi,
I have a 120GB Classic which keeps coming up with the error as below
When I restore the iPod, it restores it all right, but after syncing and ejecting the ipod, no music shows up.
Can someone tell me what is going wrong?
Here is what I have already tried.
1. the 5Rs.
2. Connecting as a disk
3. Scandisk and fix errors
4. Hard resets
Do let me know how I can fix this, dear Apple. Also do let me know if Apple would replace the device if it cannot be fixed.
Rituraj

If the On This iPod tab shows a list of songs, then they are being synced to the iPod.  Not being able to play them there (from that tab in iTunes) is normal, if you use automatic syncing. The list is probably grayed out.
I'm not sure why the songs to not appear when the iPod is being used.
Try this test.  Do a Restore again.  If it asks if you want to sync your library to the iPod during thre Restore process, decline doing so.  Also, show the iTunes sidebar, so that iTunes operates like it did before this version.  From the menu bar, under View, select Show Sidebar.  You can change that back later.
Select the iPod in the sidebar, under DEVICES.  On the Summary tab, check the box for Manually manage music and videos, if it is not already.  Apply this change, if needed.
In the sidebar, "drop down" the iPod's content list and select Music there.  To the right, is the list of songs on the iPod, which should be empty at the moment.  NOTE:  This is equivalent to the "On This iPod" tab.
Go to the iTunes Music library in the sidebar.  Using the manual method to load the iPod, drag a small number of songs from the Music library to the iPod.  When you go back to Music under the iPod, you should see those songs on the iPod's Music list.  The list should no longer be grayed out, although you still may not be able to play the songs from there (in iTunes).
Now, try the things that did not work before...  Eject and disconnect the iPod, and see if those songs appear on the iPod and are playable.

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