Snooker - sorry for not responding to this earlier, just completely missed seeing it amidst all of the other 10/1 happenings. Unfortunately there's not really much else we can try, even if we could extract the entries from that file that still wouldn't match them up with the flashcards. If you haven't yet HotSynced your Palm since the dictionary entries were corrupted, you could look in your Palm Desktop backup folder and try syncing the last version from that, but that's about the only way I can think of you could get the data back if the problem is in the file and not the filesystem (as it appears to be).
We've tested custom dictionaries with pretty large numbers of entries, so there's no intrinsic reason why it would fail if you added too many, but nonetheless you might want to consider using the built-in definitions instead of custom ones for everything; just delete the definition text from a copy of the file before you import it and the definitions should get matched up with built-in entries. Honestly most of our flashcard testing was with that setup and that's the way we think most of our customers are using it, though obviously that's not an excuse for things not working the way they should.
Dinslc622 - if all you're trying to do is restore the definitions and you're not worried about losing the associated rank data, we can actually help with that. First, go into your Palm Desktop user folder (My Computer, C, Program Files, Palm or palmOne or Palm Desktop, (your username)), open up the Backup folder inside of it, and move the PlecoDict Flashcards and PlecoDict User DB files from there to your desktop. After you've done that (and only after), HotSync your Palm and the current versions of those Flashcards and User DB files should be copied over. Send those newer versions to us in an e-mail, then install the older versions back to your Palm like you would any other Palm data files (i.e., double-click on them and then HotSync). Launch PlecoDict again and hopefully the old versions should be restored and uncorrupted again; if not, there's a very good chance we can at least recover your dictionary entries from the corrupted files.
In the future, in both of your cases I'd recommend making regular backups of the flashcard and user db files: to do this, simply HotSync your Palm and copy those two files out of the Backup folder. Also, and this is a good warning to anyone, if you encounter file corruption like this in the future, DO NOT HOTSYNC YOUR PALM; that will cause the most recent backup copies to be overwritten by the corrupted versions. Instead, move those files out of your Backup folder and then try reinstalling them to your Palm as described above.