It sounds very much like that one line is very, very long. Hence the attempt to search it for a newline is overrunning some internal buffer.
As you say Perl can process the decompress file line by line, you should pass it (the decompressed copy) through a Perl script that checks the length of the lines and inserts one or more newlines if they are over some reasonable length. Then you can recompress it.
Perhaps as a first pass, you could print out any line(s) that are greater than the maximum you might reasonably expect and that way determine whether there isn't some obvious way of 'wrapping' them such that they make sense.
With the rise and rise of 'Social' network sites: 'Computers are making people easier to use everyday'
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