Mark Burton wrote: 
Felix,

  
It's not 1605 - so I am a bit unsure which (of the 4 occurring it is).
Attached therefore my patched StyledCovernter.java file - and all my 
patches against mkgmap that I am currently using
    

That line number still doesn't make sense in your patched
StyledConverter but please enable logging at the info level and post
the messages that are output just before the crash. In particular, I am
interested in anything about splitting looped ways or too long ways,
etc.

Cheers,

Mark
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Is this what you mean with info level (logging.properties - mkgmap.log.0) ?

2009/11/16 12:01:25 INFO (StyledConverter): Splitting way SP232 (OSM id 40007220) at http://www.openstreetmap.org/?lat=45.64414&lon=8.21563&zoom=17 (making a new node) to limit number of points in this way to 251, way has 291 more points

or in order:

2009/11/16 12:01:25 FEIN (RouteNode): adding arc (http://www.openstreetmap.org/browse/way/31483911) 0
2009/11/16 12:01:25 FEIN (RouteNode): adding arc (http://www.openstreetmap.org/browse/way/31483911) 0
2009/11/16 12:01:25 FEIN (RoadNetwork): lastId = 16352 curId = 27595
2009/11/16 12:01:25 FEIN (RoadNetwork): from 45,17548/8,33472 to 45,17542/8,33455
2009/11/16 12:01:25 FEIN (RoadNetwork): arclength=15.258264110491663 roadlength=57.107363396788
2009/11/16 12:01:25 FEIN (RouteNode): adding arc (http://www.openstreetmap.org/browse/way/31483911) 0
2009/11/16 12:01:25 FEIN (RouteNode): adding arc (http://www.openstreetmap.org/browse/way/31483911) 0
2009/11/16 12:01:25 INFO (StyledConverter): Splitting looped way SS299 (OSM id 26736951) at http://www.openstreetmap.org/?lat=45.67171&lon=8.32468&zoom=17 - it has 1 following segment(s).
2009/11/16 12:01:25 FEIN (StyledConverter): delivery is not allowed in primary SS299 (OSM id 26736951)
2009/11/16 12:01:25 FEIN (RoadNetwork): lastId = 27601 curId = 27602
2009/11/16 12:01:25 FEIN (RoadNetwork): from 45,67178/8,32491 to 45,67208/8,32489
2009/11/16 12:01:25 FEIN (RoadNetwork): arclength=35.565144230907926 roadlength=35.565144230907926
2009/11/16 12:01:25 FEIN (RouteNode): adding arc (SS299, http://www.openstreetmap.org/browse/way/26736951) 0
2009/11/16 12:01:25 FEIN (RouteNode): adding arc (SS299, http://www.openstreetmap.org/browse/way/26736951) 0
2009/11/16 12:01:25 FEIN (RoadNetwork): lastId = 27602 curId = 21216
2009/11/16 12:01:25 FEIN (RoadNetwork): from 45,67208/8,32489 to 45,67208/8,32444
2009/11/16 12:01:25 FEIN (RoadNetwork): arclength=37.91620745242021 roadlength=73.48135168332814
2009/11/16 12:01:25 FEIN (RouteNode): adding arc (SS299, http://www.openstreetmap.org/browse/way/26736951) 0
2009/11/16 12:01:25 FEIN (RouteNode): adding arc (SS299, http://www.openstreetmap.org/browse/way/26736951) 0
2009/11/16 12:01:25 FEIN (RoadNetwork): lastId = 21216 curId = 27603
2009/11/16 12:01:25 FEIN (RoadNetwork): from 45,67208/8,32444 to 45,67171/8,32468
2009/11/16 12:01:25 FEIN (RoadNetwork): arclength=55.4957029221565 roadlength=128.97705460548465
2009/11/16 12:01:25 FEIN (RouteNode): adding arc (SS299, http://www.openstreetmap.org/browse/way/26736951) 0
2009/11/16 12:01:25 FEIN (RouteNode): adding arc (SS299, http://www.openstreetmap.org/browse/way/26736951) 0
2009/11/16 12:01:25 FEIN (StyledConverter): delivery is not allowed in primary SS299 (OSM id 26736951)
2009/11/16 12:01:25 FEIN (RoadNetwork): lastId = 27603 curId = 27601
2009/11/16 12:01:25 FEIN (RoadNetwork): from 45,67171/8,32468 to 45,67178/8,32491
2009/11/16 12:01:25 FEIN (RoadNetwork): arclength=19.70916502130457 roadlength=19.70916502130457
2009/11/16 12:01:25 FEIN (RouteNode): adding arc (SS299, http://www.openstreetmap.org/browse/way/26736951) 0
2009/11/16 12:01:25 FEIN (RouteNode): adding arc (SS299, http://www.openstreetmap.org/browse/way/26736951) 0
2009/11/16 12:01:25 FEIN (StyledConverter): delivery is not allowed in primary bridge (OSM id 31483904)
2009/11/16 12:01:25 FEIN (RoadNetwork): lastId = 27604 curId = 27600
2009/11/16 12:01:25 FEIN (RoadNetwork): from 45,17722/8,33191 to 45,17585/8,33472
2009/11/16 12:01:25 FEIN (RoadNetwork): arclength=268.4684682120897 roadlength=268.4684682120897
2009/11/16 12:01:25 FEIN (RouteNode): adding arc (bridge, http://www.openstreetmap.org/browse/way/31483904) 1
2009/11/16 12:01:25 FEIN (RouteNode): adding arc (bridge, http://www.openstreetmap.org/browse/way/31483904) 1
2009/11/16 12:01:25 FEIN (RoadNetwork): lastId = 27600 curId = 16351
2009/11/16 12:01:25 FEIN (RoadNetwork): from 45,17585/8,33472 to 45,17555/8,33536
2009/11/16 12:01:25 FEIN (RoadNetwork): arclength=60.58152817774872 roadlength=329.04999638983844
2009/11/16 12:01:25 FEIN (RouteNode): adding arc (bridge, http://www.openstreetmap.org/browse/way/31483904) 1
2009/11/16 12:01:25 FEIN (RouteNode): adding arc (bridge, http://www.openstreetmap.org/browse/way/31483904) 1
2009/11/16 12:01:25 FEIN (RoadNetwork): lastId = 16351 curId = 27605
2009/11/16 12:01:25 FEIN (RoadNetwork): from 45,17555/8,33536 to 45,17537/8,33573
2009/11/16 12:01:25 FEIN (RoadNetwork): arclength=34.41779048415516 roadlength=363.4677868739936
2009/11/16 12:01:25 FEIN (RouteNode): adding arc (bridge, http://www.openstreetmap.org/browse/way/31483904) 1
2009/11/16 12:01:25 FEIN (RouteNode): adding arc (bridge, http://www.openstreetmap.org/browse/way/31483904) 1
2009/11/16 12:01:25 FEIN (RoadNetwork): lastId = 27605 curId = 17892
2009/11/16 12:01:25 FEIN (RoadNetwork): from 45,17537/8,33573 to 45,17499/8,33665
2009/11/16 12:01:25 FEIN (RoadNetwork): arclength=84.20975966954433 roadlength=447.6775465435379
2009/11/16 12:01:25 FEIN (RouteNode): adding arc (bridge, http://www.openstreetmap.org/browse/way/31483904) 1
2009/11/16 12:01:25 FEIN (RouteNode): adding arc (bridge, http://www.openstreetmap.org/browse/way/31483904) 1
2009/11/16 12:01:25 INFO (StyledConverter): Splitting way SP232 (OSM id 40007220) at http://www.openstreetmap.org/?lat=45.64414&lon=8.21563&zoom=17 (making a new node) to limit number of points in this way to 251, way has 291 more points