Make sure that the menu screen size is set to your video screen size -- e.g. 4:3 or 16:9
The control for this is in the properties dialog when the menu is selected.
I've just wasted half a day trying to get encore to build a DVD because of this problem.
I put my DVD in the machine, did the pre-check and everything was fine, Had already previewed the movie with no problems but on hitting build it did something with menus, started transcoding something and then crashed and - encore was replaced with do you want to submit an error report. This happened many times over.
Looking about on the internet I thought that perhaps the different mix of video sources included in the DVD was the problem - so I re-rendered everything to the same standard AVI format using premier - and tried again - same thing.
I then thought that perhaps the menu's were the problem - and saw that the standard menu i was using had a movie in background (although it looked like a still on preview). The menu had no transcode setting on it. So I changed that and still crashed.
I then removed the movie using the menu's properties dialog. It still crashed.
I then noticed that the menus were set to 4:3 when the project was 16:9. I changed that and at last it worked - well it's building as I speak... hopefully it's all going to be OK now!
When you spend over £2000 on some software you'd like it to spot things it can't handle and tell you about them rather that dying without leaving a clue. Especially when it comes with a pre-build check facility that tells you everything is fine.