Hi Noel,
I just posted a similar issue to this. Put this at the top of your 404 page and see where wordpress is ending up.
<?php
//get filtering params
$params = array();
global $query_string;
$args = explode("&", $query_string);
foreach($args as $value) {
$query = explode("=",$value);
$params[$query[0]] = urldecode($query[1]);
}
print_r($args);
?>
For me it's trying to go to index.php?attachment=category_name. WP is trying to find an attachment page that does not exist. Are you getting a similar error? If so I'll post my fix here when I find it.