when I pasted the code given in the said page into my toolbars.cfg file and restared K-Meleon; It would simply not startup

I found that it was eating up 90% of my P4 still was unable to come up with the window( the memory was within expected bounds)

I reverted my toolbars.cfg and everything became normal

on reviewing the pasted code I found a %if.. is not having its matching %endif..

could have it caused the seen behaviour

You are exactly right. It's formatted wrong, and missing the %endif.
I'm new at this (K-Meleon), and I got the same exact result (high CPU usage).
The correct toolbars.cfg entry is as follows:

%ifplugin macros
Download Express{
macros(de)|dep_menu
Download Express Project List. Right-click for more options.
projectslist.bmp[0]
projectslist.bmp[1]
projectslist.bmp[1]
}
%endif

Rajendra prasad and PiNkY1,

I assume the Download Express Macro listed here:
http://kmeleon.sourceforge.net/wiki/index.php?id=Download+Express
is for K-Meleon 1.02 browsers only and NOT for other versions. Check to see if you guys are using the right version of K-meleon when installing the Download Express Macro.

I'm beta testing K-Meleon 1.1 RC2 and the Download Express Macro does NOT work at all.
There is NO macros.cfg file in Kmeleon 1.1 which makes the Download Express Macro useless.

It looks like Johnny Sim-Bravenboer who wrote the article will need to revise the macro to make it work under K-meleon 1.1.