Hi @Dean Murphy ,
Welcome to our forum.
In order to further confirm your issue, could you send/receive message normally on your web mail? If you also receive the error message there, the issue may be related to your account itself, and it's suggested to contact your admin to get more help.
If the issue only occurred on your Outlook desktop client, what's the version of your client(File>Office account>About Outlook), please first ensure that you have updated to the latest version of Outlook.
Based on my research, the line limit usually occurred on plain text or RTF fromat, so what's the format of your emails(HTML, plain text or RTF)? Did the issue have any differences if you switch to other formats before sending the message? Also, the option that you posted in picture may apply to the received message, so I'm afraid it couldn't affect the message you sent.
Did your recipients all work with Outlook client? In order to further analyze your issue, it's suggested to create a short message(such as with "test" word only) via New Message option and send it to yourself for testing. If you could send to yourself normally, the issue may also be related to the recipients' client.
If you also couldn't send it to yourself, in order to avoid the interference of add-ins, it's suggested to restart your Outlook in safe mode to check if the issue still exists(Windows + R>type "outlook.exe /safe">enter).
Hope that would be helpful to you.
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