962mb seems to be ok because formatting and system files make the difference.
So to confirm, after formatting, it fixes the "disk error" messages right? Then a few days later, it comes back on again? Durin those days, have you changed, add, remove any of the files stored in your player?
Definately take daveislander's advice and follow the guide on how to remove a hack just in case your player has been hacked.
What you can also do is a checkdisk on your player's drive from Windows to see if it fixes any possible corruptions in the memory sectors and blocks.
It could well be that the physical memory block has some bad sectors on it. I know I've had one MP3 player that had a bad memory block.
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