hi there
I had the same problem. So what i Did was i unchecked the most recent songs on my list and set my ipod to copy only checked songs. That didn't work there was the error so what i did was i went to my preferences and set my ipod up to not copy any podcasts. Now its working fine all i need to do now is check and unchecked each podcast to see which one has the bad file name. And then unscribe from that podcast feed.
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Machine Name: iMac running on Tiger
Machine Model: PowerMac2,2
CPU Type: PowerPC 750 (83.2)
Number Of CPUs: 1
CPU Speed: 450 MHz
L2 Cache (per CPU): 512 KB
Memory: 768 MB
Bus Speed: 100 MHz
Boot ROM Version: 4.1.9f1
ipod 4gen 20gb