I'm no expert, but I've had my index "issues" over the years.
I think anyone wanting to help you will want to know whether you've
tried using the Binary Index setting in the Project Settings.
We have projects with much bigger HHK files than yours, so
that's not the problem.
Have you opened up the HHK file in Notepad (or other text
editor) and taken a look?
We had the type of problem you described when we imported
topics from a different project and
those topics had keywords saved in them (instead of in that
project's HHK file. This was caused by a bug in RH X5.
If you did that, I can give you the workaround we used.
(Sorry if the formatting below isn't ideal -- I'm just going to
paste the whole thing in from a different source.)
Warning: It is time-consuming if there are many keywords to
fix.
1. With the project closed, have someone with MS Access open
its .cpd file and print out KKeywordList. From this printout you
can see which keywords are causing the problem, because the
problem-causing keywords have a negative value.
2. Delete the .cpd file.
3. Make a backup copy of rhkkeyword.apj.
4. Using Notepad, open rhkkeyword.apj and add the problem
keywords manually in this format:
<keyword>
<name>Testing</name>
<keywords/>
</keyword>
Multi-level keywords are inserted as follows:
<keyword>
<name>first level keyword</name>
<keywords>
<keyword>
<name>FIRST subkeyword</name>
</keyword>
<keyword>
<name>SECOND subkeyword</name>
<keywords/>
</keyword>
</keywords>
</keyword>
Warning: The
<keywords/> tag occurs only once for each main
keyword, and it occurs after the last subkeyword, if any, as shown
above.
5. Save and close rhkkeyword.apj.
6. Reopen the project and click the Index tab. If RoboHelp
fails to open or crashes, then you know there are syntax errors in
rhkkeyword.apj. Delete the .cpd file, fix rhkkeyword.apj and try
again.
7. When RH's index is displaying properly, check for any
subkeywords whose main keywords are not defined. (These appear
bolded.) For example, if you have "batching\grouping" but not
"batching", add "batching" to a topic.
8. Recompile help and check it carefully.
Hope this helps.
Eileen