Right, what I've done is I've copied from the Zune, any music I didn't have on the PC, completely wiped the Zune (using the back + center + play button combo) and plugged it in. It auto-installed the firmware to 3.1 again and now it works just fine. I just have to put 15Gb of music onto it now.
The program I was using was the Zune program and I'd set it to 320kbps quality. It was working under the same settings about two weeks back so I had no reason to assume it was a settings change causing the problem. It seems pretty clear that it's a firmware corruption to me. I was on v3 software and 3.1 firmware.
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