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I had exactly the same thing happen. When I looked at the raw RTF file it looks like Word was applying formating to each individual word rather than to paragraphs (as is more standard).
Unfortunately, I don't know what else to have you try. I just called it up in Wordpad and saved, but my "base" file was about 500KB that expanded to 20M or so, so it didn't take that long (10-15 secs) to save.
The only thing I can think of is to split into small pieces and then cut and past them back with wordpad.
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