Hi aquCHAOS.
1. What format are you using for the textures? Have you placed them in the same directy as the exported avatar?
2. Under normal conditions, the problems you are seeing only happen when a mesh is exported onto a different skeleton than the one it was skinned to in max. If you'd like, I can take a look at the model.
3. So far, the most complex avatar we have exported was made up of 30,000 triangles, though this is much more than generally needed in most cases. This type of crash usually occurs when running out of RAM while exporting. As this sort of thing usually goes, the way to fix it is to reduce ram usage by closing all other open programs, buy more ram, increase your virtual memory allocation. Depending on your version of windows, it may also be useful to look into using the
3gb switch.