It sounds like it doesn't like something about the subject string. There is a logging statement that may help us see what the subject string looks like when this error happens.
if (log.IsDebugEnabled) log.DebugFormat("In SendEmailNormal({0}, {1}, {2}, {3}, {4}, {5}, {6}, {7})",
from,
to,
cc,
bcc,
subject,
messageBody,
html,
priority);
To enable this, you can change the logging level in log4net.config
from this:
<level value="INFO" />
to this
<level value="DEBUG" />
then cause the error and see what gets logged as the subject. It will make the log very noisy so you will want to change it back afterwards.
Hope it helps,
Joe