Quote - Any scene I use her in seems to save OK. But when I try to re-open afterwards, whole scene won't load at all

Did you look at the Renderosity thread linked in my previous post ?

If you've turned off the "Use external binary morph targets" option, you should be able to reopen scenes saved after you turned it off.
Scene saved before you turned it off need to be recovered.

You could try redownloading/reinstalling V4.1as I believe the problem has been fixed (I would still recommend turning off the mentioned option for P7, for P6 you have no choice).