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The code is fairly explicit here; there's definitely logic to close off a file when it reaches 50,000 but it's clearly over-running in some cases here.

I think the quickest solution for now is to reduce the limit from 50,000 to 40,000 which should mean if it continues to overrun then it still shouldn't exceed 50,000.

This can only be changed by editing the code. The necessary file is src/XF/Sitemap/Builder.php. Find:

[code=php]const MAX_FILE_ENTRIES = 50000;[/code]

Replace with:

[code=php]const MAX_FILE_ENTRIES = 40000;[/code]