The same problem with GP-service.
My model returns a set of features (GPFeatureRecordSetLayer).
When there are many features in the result everything is ok.
But if there are a single feature, REST crashes.
Error Executing Task
Code: 500
If I change the task to be async, it returns an error, that XML document contains an error.
I am not using route event layer, but it looks like it's a common problem.
It works fine in ArcMap.
ArcGIS Server 9.3.1.