So you created an Illustrator file, saved it as pdf, made some changes and now can't save as ai unless you rename it? I haven't personally had that problem, but I usually save as eps instead of ai (so it's compatible with Quark). I would look at Adobe's website to see if this is a known issue.
I’ve got that error before when saving as PDF. Most of the time its an insane AI file. I believe I resolved the error by turning off the “preserve Illustrator editing capabilities”.
Though I always keep an original ai file.
Getting that error saving AI files, don’t know what to tell you there.
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