auto assign role is assigning too many roles on registration

I tried what you suggested and had no joy i'm afraid, it's still doing the same thing :(

Errr, wouldn't know where to start to give you that info, I have only been using drupal for a few weeks and am a total newbie, although learning quickly (am having too). Would I need to download a debug software to get that info? Any guidance on what to do would be appreciated!
Not sure if any of the info I give here will be of any relevance but just thought I would mention it just incase:

Am working on localhost through XAMPP.

I have installed a similar module, register_with_approval just to see if I would get the same outcome but that works fine, correctly registering the separate roles on registration. I would really like to get this sorted as the auto assign module is a lot better suited to what i'm after for my site than the register_with_approval module.

I have looked in the autoassign_role.module file and "think" I have found the lines of code (lines 165, 221, 230, 239, 249, 260) and put the print_r($user_roles); directly after these lines. I tried a test registration, checking only one of my role checkboxes, when submitted a page came up saying:

Array ( [3] => 3 [4] => 4 ) Array ( [3] => 3 [4] => 4 ) Array ( [3] => 3 [4] => 4 )

Not a clue what that means or if that gives you a hint as to whats going on. Here's what I did to the code, sorry for the length, just thought it would be worth you looking to see if I had done it correctly as I am unsure:

if (_autoassignrole_get_settings('user_active') == 1) {
        $roles = array();
        $user_roles = _autoassignrole_get_settings('user_roles');
        print_r($user_roles);
        if (is_array($edit['user_roles'])) {
          foreach ($edit['user_roles'] as $k => $v) {
            if ($v != 0 && in_array($k, $user_roles, TRUE)) {
              $roles[$k] = $v;
              print_r($user_roles);
            }
          }
          $edit['roles'] = $roles;
        }
        elseif ($edit['user_roles'] != '') {
          $edit['roles'] = array($edit['user_roles'] => $edit['user_roles']);
        }
      }
      if ($rid = autoassignrole_get_active_path_rid()) {
        $edit['roles'][$rid] = $rolenames[$rid];
      }
      if (_autoassignrole_get_settings('auto_active') == 1) {
        $auto_roles = _autoassignrole_get_settings('auto_roles');
        foreach ($auto_roles as $k => $v) {
          $edit['roles'][$k] = $rolenames[$k];
        }
      }
      $account = user_load(array("uid" => $account->uid));
    break;
    case 'register':
      if (_autoassignrole_get_settings('user_active') == 1) {
        $roles = user_roles(TRUE);
        $user_roles = _autoassignrole_get_settings('user_roles');
        $path_roles = db_query("SELECT rid from {autoassignrole_page}");
        while ($path_role = db_fetch_object($path_roles)) {
          unset($roles[$path_role->rid]);
        }
        foreach ($roles as $k => $r) {
          if (!in_array($k, $user_roles, TRUE)) {
            unset($roles[$k]);
          }
        }
        if (count($roles)) {
         $form['autoassignrole_user'] = array(
           '#type' => 'fieldset',
           '#title' => _autoassignrole_get_settings('user_fieldset_title'),
           '#collapsible' => FALSE,
           '#collapsed' => FALSE,
         );
         if (_autoassignrole_get_settings('user_sort') == "SORT_ASC") {
           uasort($roles, '_autoassignrole_array_asc');
         }
         else {
           uasort($roles, '_autoassignrole_array_desc');
         }

         if (!$edit || !array_key_exists('user_roles', $edit)) {
           $edit['user_roles'] = array();
         }
         if (_autoassignrole_get_settings('user_selection') == 0) {
            print_r($user_roles); 
            $form['autoassignrole_user']['user_roles'] = array(
             '#type' => 'radios',
             '#title' => t(_autoassignrole_get_settings('user_title')),
             '#options' => $roles,
             '#description' => t(_autoassignrole_get_settings('user_description')),
           );
           
         }
         if (_autoassignrole_get_settings('user_selection') == 1) {
             print_r($user_roles);
             $form['autoassignrole_user']['user_roles'] = array(
             '#type' => 'select',
             '#title' => t(_autoassignrole_get_settings('user_title')),
             '#default_value' => '',
             '#description' => t(_autoassignrole_get_settings('user_description')),
           );
          
           if (_autoassignrole_get_settings('user_multiple')) {
             print_r($user_roles);
             $form['autoassignrole_user']['user_roles']['#multiple'] = TRUE;
             unset($form['autoassignrole_user']['user_roles']['#default_value']);
           }
           else {
             $roles[''] = '';
           }
           $form['autoassignrole_user']['user_roles']['#options'] = $roles;
         }
         if (_autoassignrole_get_settings('user_selection') == 2) {
             print_r($user_roles);
             $form['autoassignrole_user']['user_roles'] = array(
             '#type' => 'checkboxes',
             '#title' => t(_autoassignrole_get_settings('user_title')),
             '#default_value' => $edit['user_roles'],
             '#options' => $roles,
             '#description' => _autoassignrole_get_settings('user_description'),
           );
         }
         if (_autoassignrole_get_settings('user_required')) {
           print_r($user_roles);
           $form['autoassignrole_user']['user_roles']['#required'] = TRUE;
         }
         return $form;
        }
      }
    break;
  }
}

Sorry, I dont have irc (didnt know what it was, had to google it) so i've just followed your instructions and have got rid of the print_r's and added the print_r($value) on the line you said.

it comes back with:

user_activeuser_rolesuser_fieldset_titleuser_sortuser_selectionuser_titleuser_descriptionuser_selectionuser_selectionuser
_requireduser_activeuser_rolesauto_activeauto_roles