http://msmvps.com/blogs/steveb/archive/2007/08/24/can-t-open-or-save-an-attachment-in-outlook-2003.aspx
What's
 even cooler, is that "Netfelix" created a batch file to remove the temp
 files from user's profiles who are running into this a lot.  Below is 
what he posted: I've created a batchfile for my users that have run into this problem 
del
 "c:\documents and settings\%username%\local settings\temporary internet
 files\(OLK folder name)\*.pdf" The OLK foldername can be found in the 
registry, as stated before, by searching for "OutlookSecureTempFolder"
This
 was a great way to end the day finding a great and accurate answer, 
seeing that there is hope after all for Live Search, and that the 
TechNet Forums had the answer in there while the KB articles were a bit 
lacking in that they kept referring to long file names.