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firmware update will take a few minutes and will reset your Zen several times, this is normal.Do not remove the usb or charge cable until the firmware update tells you it has completed.As far as i know the Zen will take any size of hard drive as long as it is a laptop drive that is 9.5mm deep 2.5" wide.I recomend the Hitachi Travelstars as they are reliable and cheap. now slide the cover off and you will expose your hard drive and a copper foil type thing.Now grab your flat head screwdriver and slide it in the gap at the bottom where the hard drive connects to Zen.
(one of the screws has a warrenty sticker, removing this invalidates your warrenty) the latch to the right to pop the front cover off.Now hold the hard drive into the Zen and flip the Zen over so you can put the four big screws back in and mount the hard drive onto the Zen. Careful not to put too much pressure on those screws they are very fragile! Now you need to switch the Zen back on and select format all.