|""Which email program are you using that this happens with ?""|
"The email program is in IE7"
I don't know of any email program that's built into any version of IE, but Windows itself has Outlook Express built into it.
In most cases, you can also access your email via an ISP provided Web Mail program.
If you can do that, have you tried printing email in that ?
""You DO have to select a printer friendly version of a web page sometimes.""
"Not sure how one does this! never required this before problem occurred."
Many web pages have a button top rght labelled Printer Friendly Version or similar.
However, not selecting that would only affect printing some web pages and would not account for...
""Which web pages that churn out many pages of HTML script ?""
"Any web page, all seem to activate the same with varying page amounts"
The only time that has happened to me was long ago with a dot matrix printer that I had set the wrong printer emulation for.
It was connected via a parallel port connection - parallel port connected printers are not Plug-n-Play detectable, so Windows has no way of "knowing" whether the printer emulation you select is correct.