Thanks for the highly ihformative description of the error. Your problem is that the version of IFILoader you're using is too old to handle the size of the program you're trying to send to the robot controller. I'm guessing you have version 1.0.10 installed, from the 2005 competition season.
Go to
http://www.ifirobotics.com/rc.shtml#Programming and upgrade to version 1.1.0 (or later if it exists).