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With XP the partition size shouldn't really matter.
I used to work in Dixon's PC service call centre (shudder...) and we saw this error a lot on the new (at the time) XP boxes.
If memory serves me correctly, hal.dll gets modified on bootup if the system's hardware configuration has changed, but problems with it can be a real pain in the bum. One of the first things we'd try was to make a change in the computer's bios.
Try this: go to the BIOS setup and find the power management options. Don't change anything drastic (like enabling or disabling APIC, ACPI, and other stuff) but see if you can find a suspend / standby mode option. It's usually set to "S1: POS" or "S3: STR" (power-on standby & suspend to ram respectively).
Change that option to whatever it's not set to, save the changes and try to boot the OS that's not working. If it still doesn't work, try changing something else in bios like disabling the CDRom IDE channel and rebooting.
As a last resort, copy the hal.dll file from your XP installation CD (if you can find the file - I don't know where it usually is, but you might need to trawl through the .cab files) to overwrite the broken one. Of course, you'll need to boot OS 1 to overwrite OS number 2's broken file.
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I miss my home cinema
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