My iPod Classic syncs some music on and then corrupts and wipes... Help?

I decided to restore my iPod Classic 160GB because it was running a little slow.
I have since on numerous times over the past few weeks tried to restore all my music back onto the device but I've came up with the same problem everytime.
Everytime I sync it, it gets to around 10% of my music library onto it and then corrupts and wipes itself and demands a restore.
I've tried everything with the files. I have put them into sepreate smaller playlists, I've ticked and unticked them all and I've restored the library itself but not to any avail.
Can anyone help me?

The iPod hard drive has bad sectors, a replacement hard drive will resolve your issue.

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Just wanted to post my results, for future users benefit:
Putting my Ipod into Disk Mode, connected to computer, Itunes recognized it, performed a Restore.
Still had syncing/freezing issues.
Decided that my Itunes library database was corrupted. Went into My Documents > My Music, and deleted the Itunes Folder, except for the containing Artwork Folder.
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IPod Classic sync problems

I'm using an iPod Classic. It's 160GB and it's the newest (ish) generation of it. I haven't had any problems syncing it in the past until recently after the latest iTunes update.
My computer recognises my iPod when it's connected and so does iTunes. I've run diagnostics on iPod connectivity, it passes iPod connectivity, but not the device sync test, even though iTunes clearly recognises the iPod is syncing. Beforehand, I had reset my iPod thinking the sync issue was something with my iPod'a hard drive but i had done a check using diagnostic mode and my retracts and reallocs were both at 0 which I assume is very good for an iPod I've had for 3 or 4 years.
The battery is fine and the hard drive seems to be fine. I've even tried both USB ports on my laptop (Toshiba with Windows 7 Home Edition).
I even went and uninstalled iTunes itself (but none of the add-ons) and I'm still having issues.
At the moment it's showing I have 7GB of music when there's only 234 songs on it.
I've also done a reset several times by holding down the menu and center button but it's still not syncing my music properly, still saying I've got 7GB of music when there clearly isn't
if it helps my iPod Classic is using the latest version, 2.0.4 and my computer's software is up to date as well.
I'm also going to try to format the hard drive on it to see if that does something but I doubt it'll help.
if anyone has any advice on how to fix this that'd be great

Hhhmmm!
Not actually sure what your question is.
That said, it appears to centre on the fact that you have 234 songs taking up 7GB of storage. Is that correct? If so, there are two possibilities.
How do you arrive at the figure of 7GB? Is it only the music, or is it all of the storage being used on the iPod? With the iPod connected to your iTunes Library, check to see how much storage is being used by each type of media. In particular, how much "Other" is being used? Hold your mouse over each section so that the info balloon appears and read off how much storage is being used by each type. The crucial section is the Other (as indicated in the screenshot below).
Perhaps most, if not all of your music is encoded at a very high Bit Rate. What format are you using to import from your CDs? Check several songs and make a note of the Kind, Size and Bit Rate. Then post back with that information.

My iPod Classic syncs some music on and then corrupts and wipes... Help?

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