I fixed this error by right clicking on the internal storage withing the player, formatting. Then copy one song to the flash, and while it is still plugged up to the computer, double click on the song within the flash it'self as if to play it on the computer. Allow it to play a little and then disconnect the player from the computer. Play the song that you copied. Then you can re-attach the player to the computer and copy songs back on to it.
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I had this same problem. If I tried to turn the player on, it just gave me the "format the player" screen. If I turned it off (by removing the battery if necessary) and plugged it into a USB port, it could still be read as a flash drive. I could copy the files to a backup folder on my computer and then (using Windows) I could right-click on the drive and choose Format. When it was finished, I disconnected it from the computer and turned the player back on and it was able to boot normally (it took a little while, but it worked). After rebooting, it automatically recreated the MUSIC.LIB, MUSIC.SEC, SETTINGS.DAT system files and the VOICE directory. I plugged it back into the USB port and copied the music back onto it and it worked fine. So... back up the data and format the player...