Rio carbon can figure out how to get the download into the rio

Sorry, Rio kinda went bust some time ago so to my knowledge there isn't anywhere that does repairs anymore.

See: Replace broken scroll wheel on Rio carbon for help on how to DIY.

Hope this helps,

Mowcius

You must use the native software - still available on rio's website. No other transfer method will work with this player.

The easiest and least damaging way to open the Rio Carbon is to start at the bottom of the player and pry it open a little until you can see the tabs. You have to push those to release them. Work you way around clockwise and there are tab a little further into the player, you have to pull the bottom of those out to release them. I did it last night and was able to repair the volume wheel and get the player back together and it works.

I tried you solution mowcius (except the part about burning it) and it didn't work. It showed up as an unrecognizable USB device in windows Vista and nothing I did got rid of the "Upgrader" screen.
I did get it to work, but remember the stuff I did could destroy the player. It worked for me, but if it hadn't I was going to pull the CF card and chunk the player.
I plugged the  2100 into Vista. Vista stopped responding during a file transfer and the 2100 went into "Upgrader" mode. Nothing I tried worked. A google search gave me this page so i tried it. 
I wasn't going to spend money on a CF card as I already have the broken volume wheel, so I thought "what if I took the CF card out, put it in a CF card reader, re-formatted it, reinstalled it into the 2100, then re-installed the firmware". 
I did that, but I couldn't get the "Upgrader" screen off during all of this. So I figured I'd try something that would either clear it or destroy it - i used a screwdriver to cross the positive and negative leads on the battery for a second. The screen went blank and I figured it was dead as it wouldn't respond to the power button. I plugged it in with the USB cable and the Firmware flash program saw it finally. I reinstalled the firmware and now it works fine. 
This may or may now work since crossing those wires could've burned the whole thing up or blown the battery up. I did this knowing these undesirable results were more than possible. However, it appears to have worked. 
If you're going to chunk yours and don't care about a possible fire/explosion you can try this.

U will have broken your hard drive...

try replacing it with CF card

Everybody says that this does not work but it definitely does!

My Rio got dropped and I completely buggered the hard drive so after reading many forums saying that it didn't work I read one that said that someone had told them that sandisk ultra II ones worked (very vague!)

Because I had nothing to lose I went out and bought a 1GB sandisk Ultra II CF card. I then took apart my rio and replaced the hard drive with the CF card. Still not thinking it was going to work I plugged it into my computer and installed the latest firmware (from the rio website) and then HEY PRESTO!!!!!! it works.

I have yet to try an 8GB ultra II card but when I do i will keep you posted.

If you don't believe me then I don't blame you but If you send me a request then I can send you pictures and more details...

Rio will live on

Hope this helps

Mowcius

This is a hardware issue - there is no repair svc for this one. sorry.

http://www.content-type.com/1461305906/carbon+3.04.EXE.htm This link takes you to a site which will allow you to download an upgrade to your carbon's software which includes a volume option in the settings menu. My wheel broke a while ago too, and I bought a new player before I found this link. I still think this is the most compact and portable 5gb player on the market. I'm back to using it now.

replaytv.com is the new location of Rio Carbon

I think you should keep looking for another solution, but what i know is that for out of warranty carbon players you can't get it fixed through rio/sonic blue, they will only replace it for a new one/remanufactured one for 99$. Here's a link to a previous post of someone who had the same problem as you: http://www.fixya.com/ThreadView.aspx?thid=101466&prdid=230965 Good luck

It is easier to fix it yourself. Very carefully take off the faceplate (you can put it back on later using a hair dryer). There are two slots there that you can use to release the back casing. I used an eyeglass screwdriver to gently press down on the catch. There are three other catches on the back - one on each side and one on the top by the headphone jack. Be extra careful when releasing the top one. Once you have the back cover off, it is easy to see where the wheel has broken. I used a two-part epoxy on the two places of the volume wheel that had formerly attached it to the control and put it back in place. Once this has dried, replace the back cover and use a hair dryer to heat the adhesive on the face plate. Stick the face plate back on, and you're done.