The KVIrcPortable.nsi is missing the registry::unload so it leaves the registry plugin behind in %TEMP%\nsr26.tmp or a similar folder.
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I've fixed it in local source and recompiled. John, if you want to add and recompile and push a Rev that's fine...it's not a big bug, so it's your call.
This is fixed in 4.0.4 revision 2.
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