You need to save the xml for the profile you use, its located in the main Mach3 folder. Also if you have custom macros then save them, same for offsets and tool tables, all three are located in the macro folder then the profile folder. Any brains you have made will need saved, they are in the brains folder. Same for any plugins you use, save them, they are in the plugins folder. If you have a custom screenset save it and its bitmaps and lastly any licence files you have. Mach is called Mach1Lic.dat and the NFS wizards is called Wiz.dat.
Think thats about it.
Hood