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When I connect Ipod to computer via usb, vista reports "USB Device Not Recognised, one of the USB devices connected to this computer has malfunctioned and windows does not recognise it. For assistance in solving this problem, click this message. So begins a wonderful journey of discovery, Vista says to replace it, itunes suggests all the usual 5r's and several others which end up coming full circle. I have followed every suggestion on the site. The ipod classic 80gig is fully charged and is operating normally, I just cannot get it to sync with itunes 8. When I last connected it to itunes 8 I had been constructing a new play list and this unfortunately replaced all existing tracks etc on the machine, so instead of several hundred tracks I have 42, which play well but it is no longer entertaining. How do I get it to sync again? Surely there is a solution other than the bin?

First try to determine if the issue is caused by vista or by the iPod. The fastest way to do so is to connect your iPod to a different computer. If you get the same message "usb device not recognized", and the ipod will not even show up in windows explorer (as external hard drive) then there is an issue with the iPod classic motherboard. If you can transfer data using another computer (preferrably start by just copying files using windows explorer to rule out itunes trouble) then the issue is caused by vista and you can expriment with downgrading to lower version of iTunes.

I have tried three computers, all do not recognise the ipod, one of them is XP the others vista. I also tried a different ipod with them and it was identified by them and by my computer. So it is clear that you are correct that the fault is with the motherboard.
Thank you for your help.

i have this same issue and i tried to download a lower version or itunes with no luck, i even uninstalled and reinstalled the usb drivers with no avail... what other options are there?
please help!