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The Rio Carbon is completely incompatible with iTunes (which uses AAC format). It only accepts mp3, wma, and some WAV's. The Rio Carbon is still the best mp3 player I ever owned, but since Rio doesn't make them anymore, it will never be compatible with iTunes. You can use it with Rhapsody's Mp3 Only service, or any music service that gives you the files in mp3 format - but you can't sync the songs through the music service's "synchronize function" - you have to download the files to a location on your computer, and then use the Rio music Manager to transfer the songs to your device.
Try taking out the hard drive and see if your pc recognizes it. If not then try flattening it (could take some time!) and recharging it multiple times. If you can get it to recognize it then try replacing the hard drive with another or a CF card (see: REPLACE BROKEN HARD DRIVE IN RIO CARBON...) If it does not recognize then I'm afraid there is probably something else wrong with it that probably involves the main circuitry and I can't help you with that.
I had the same problem. I smacked the back of it (in my hand, not off any surface) to try to release the pin stuck on the hard drive. Rio Carbon currently works for me, but I will not expect too much. I have had mine for awhile now.
This is probably only a temporary solution, in the long run your hard drive will most likely get stuck again.