Knights Reborn

well im not an expert, but have you tried a clean install? i know thats the last thing anyone wants to hear =\

You are correct, this means the config file is too big. Have you run JKA as a server? With the base game, it will load all client and server settings in to your config file and make it too big to load. Most of the server settings you don't need if you plan on playing on someone else's server.

If you don't know which settings to get rid of, my recommendation would be to delete your jampconfig (from base and from japlus if you use the mod) and start fresh. You'll have to rebind all your keys (unless you save it in a script!), but it will start your file over and make it small enough to load. Also, to prevent this happening again, you can do /writeconfig (name) while in game to save these settings to easily load them if your jampconfig gets overloaded again.

Use OpenJK.
Also a good idea to do cvar_restart and then hand-write a separate cfg that is automatically executed (add "exec myconfig.cfg" to autoexec.cfg) so it won't overflow from having too many cvars that are saved to cfg by default.

This is typically an issue after swapping out multiple code mods, joining a siege server or launching your own server by using map/devmap. Each of these things add a large amount of cvars that are to be saved to jampconfig.cfg
OpenJK increases the limits.

Thank you everyone for your helpful replies. I have tried everything, to no avail. I seemed to have fixed it now though, but I had to perform a system restore on my PC. Sent it back a week and no issues. It was very strange lol. Thanks again guys !