Hi Kyrylo-Tadei Krukenytskyi | KKR,
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Have a good day and I hope you're doing well!
Based on your description that it affects only one user, works temporarily in the "New Outlook" experience, and happens randomly, I agree with your assessment. This strongly points to a client-side corruption or a specific environmental conflict on that machine (Windows/File System level) rather than a server-side issue.
Based on my research, please try the following troubleshooting steps in this order:
1. Create a completely new Outlook Profile: You mentioned deleting the PST, but sometimes the corruption lies within the Outlook Mail Profile configuration (Registry/Cache) rather than the data file itself.
- Go to Control Panel > Mail > Show Profiles > Add.
- Configure the email account again in this fresh profile and set it as "Always use this profile".
- Test saving an email here.
Reference: Create an Outlook profile - Microsoft Support
2. Test saving to a "Clean" Local Directory: We need to rule out long file paths or permission inheritance issues.
- Create a simple folder directly on the C drive (e.g.,
C:\TestEmail). - Ask the user to save the email directly to this folder.
This ensures the folder is strictly local, has no complex permissions, is not redirected, and is not subject to the 255-character path limit.
3. Temporarily Disable OneDrive / Folder Redirection: This is a very common cause for 0 KB files. The process of saving a .msg file depends on stable local I/O.
- In environments with OneDrive Known Folder Move (Backup for Desktop/Documents), the sync engine might attempt to upload the file handle immediately after it is created (at 0 bytes) but before Outlook finishes writing the data stream. This conflict results in an empty file.
- Please Pause OneDrive syncing and ensure the user is not saving to Desktop or Documents if those folders are being synced. Then test again.
4. Test on a different Windows User Profile: If all the above fail, the corruption might be located in the Windows User Profile itself (Registry hives or User-specific permissions).
- Please try logging into that specific machine with a different Windows user account (or create a new local test user).
- Setup Outlook and try to save the file.
- If it works on the new Windows user, the original Windows User Profile is likely corrupted and needs to be recreated.
Reference: Create a local user or administrator account in Windows - Microsoft Support
I hope this helps you narrow down the cause and gives you some reasonable insights for troubleshooting, at least partially. If you have any concerns or questions, or if I misunderstood or was unclear about anything, feel free to reach out.
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