So I uncheck album artwork and that got rid of the majority of the data now I have 83.4MB of other 26.35GB music & 1.46GB Free. I am now on sync to selected playlist witch has all my music in it but no playlists, but I click sync all music & playlist's itunes tells me there is not enough free space 3.49 required 1.46 available. but my iTunes library is 26.35GB so it has all the music but know playlists. Dose this mean my playlists take up 3.49GB?
If you have all of your music on there and the playlists are subsets of that music, this shouldn't be an issue. It sounds like iTunes thinks there is additional music that is part of the playlists that are not already on the iPod. Is there?
Your best bet is to delete the music from the iPod and then re-sync it to just the playlists, that way you can have both.