Modern SATA and IDE disks are not perfect, in the old days the defect list was printed on a label on the drive and you had to laboriously type in the defects head/cylinder/sector ....these days it's all automated and hard disks have spare cylinders which allow you to map out the bad sectors and give the impression of a defect free hard disk....the truth of the matter is though that all disks have defects and bad sectors...when a drive develops a bad sector that cannot be corrected by ECC it won't map it out until the sector is written again and fails on a write command.....there are various ways to do this.... In linux it's relatively easy with the following
dd if=/dev/zero of=/dev/sdX bs=64MB
that will write zero's from the start of the drive to the end of the drive, obviously you will have to change the sdX to whatever the drive has been allocated by the operating system, and I cannot say enough how RIGHT you have to be about the correct /dev/sdX ....DD is very unforgiving it won't prompt you are you sure.....are you really really sure ....it will just write out zero's at the full data rate of the drive and if you're talking SATA then in less than a few seconds you'll have overwritten everything important on the wrong drive.
Seagate tools does a similar thing, there is no such thing as a low level format any more it's simply a method of kicking the bad sectors into touch with the drives firmware.
I've revived many hard disks this way, the only ones that totally fail are the ones where either the electronics have failed OR sector zero the first part of the disk has developed a fault, that cannot be mapped out, because partition and boot information sit on sector zero...if that's got a bad sector throw your drive away pointless even trying to fix it.... I've got a 500 GB drive in my Humax 9160T that has got a bad sector or two, I'm whipping it out tonight and zeroing it with DD, I'm confident it will fix the jumpy playback at certain points in recordings as they hit the same bad sectors .....Just thought I'd share my experience....Humax use their own filesystem its based on EXT2, but it's not mountable on a linux box, I suppose it's possible if we knew the structure, the good thing is DD can be used again to copy a similar sized hard disk to another AND keep the humax format....
dd if=/dev/old-disk of=/dev/new-disk bs=64MB
will clone the old disk to the new disk at the sector level so everything is preserved including your recordings... Clonezilla can probably do it as well, but I prefer to use DD because it's just faster.
Haven't got linux ? simple just download a live CD/DVD version burn it to DVD or CD and boot that in your Windows box DD comes standard in most if not all linux distributions... booting a live version will not destroy your Windows system.... just be VERY careful to make sure you are squirting the data from and to the RIGHT hard disk.
I used to be a hardened Windows user many years ago, I never thought I'd jump ship....but once you do, you'll realise linux does things faster, better and with less hassle than Windows ever did or can do