Platfrom: Windows 7 (32bit), GE 1.4 (not 1.5, sorry!)
After assigning a .ico file to my game under Game Preferences, future exports crashed immediately. An exe file was still produced but it did nothing but crash when ran. I tried various .ico files, made by myself and downloading premade ones, and the crash still happened.
I used the merge command to merge my game into a blank new game to remove the .ico association with my game. (This was the only way I could find to do this, rather frustrating.) After the merge, I was able to export without trouble so I'm fairly certain it was the .ico association that caused the problem.
Can anyone else confirm this?