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I've seen this before. The previous customer who reported it decided to fix the filenames, so the problem "went away".
If the filename is accepted during crawling, it's definitely a bug if it causes queries to fail. Can you log an SR with support so we can get this logged properly as a bug, then we can try to get a fix for it.
Scarbo: I believe the problem is not just around using the % as part of the query - if the document with the faulty URL (the URL being derived from the filename) is included in the result set then it will cause the failure regardless of the search expression used.