I am drinking dark beer!
Some file is making the problem. You should figure out which one is it and delete it. Most of the time the problem is coming from the files GUPDATE.GCD, .img, .gpi (those in folder POI), srf (those in Vehicles), .gpx (folder GPX), scrn, Voice (.vpm) etc. If you wish delete every of those files and after that flash with the normal firmware - 058001000490orig.rgn. See if that is going to help.
First make back up of the files...
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