Serious issues saving drawings as .AI (Adobe Illustrator)!!

First, I need to be able to export SolidWorks drawing filesas .AI's and I can. Small assemblies, and assemblies from variousprojects, "save as" .AI normally, and open in Illustrator with noproblems. My drawing artwork saves as vector artwork, part andassembly artwork saves as bitmaps. Fine, that's what it's supposedto do.

Now, I have ONE very large assembly DRAWING that saves as a bitmap- a low resolution one, at that - and I cannot determine as toWHY?? I'm really starting to get annoyed here. I createillustrations for service/maintenance manuals. My writer has askedfor various views of this ONE assembly, but I just can't deliverwhat he needs!!

As work arounds, I've created a SpeedPak of one subassembly in thislarger assembly - the most complicated subassembly - so the fileopens quickly and can be manipulated easily in SolidWorks. Beforethis assembly wouldn't even open without crashing SolidWorks. Withthe SpeedPak, it opens easily.

When I "copy to Adobe Illustrator" the artwork pastes as vectorartwork, but the SpeedPak'ed subassembly appears as ONLY THE FACESI'VE SELECTED FOR MATES.

Out of curiousity I've saved the drawing artwork as .DWG andbrought it into Illustrator to find that tho it is vector artwork,some parts of the assembly are wire frame, while others are hiddenlines removed. Weird.

I'm guessing there's something corrupt in my assembly, most likelyin that one subassembly, but I've recreated the subassembly fromscratch a few times now to determine what/where the model has gonefunny. But, I've found nothing obviously wrong with the file.

I've recently upgraded to SolidWorks 2009 SP2, and would like tonote that SolidWorks stability has gone right the Hell out thewindow, BUT ONLY WHEN DEALING WITH THIS ONE ASSEMBLY.

Please help if you can!!SolidworksDrawings And Detailing