I too was having this problem.

I downloaded the source with apt-get source and twiddled with various
CFLAGS and configure knobs, but really that was a waste of time, because
i get a working mplayer binary with CFLAGS empty and no defaults on a
G3. My guess is that this is a bug in the mplayer configuration system -
they sternly warn you not to override CFLAGS (even if it's to provide a
more compatible -mcpu= option!) If I add -mpowerpc-gpopt to CFLAGS,
boom, the SIGILL's come back. Remove them again, and it builds fine.
These CFLAGS, for example, work fine:  "-mcpu=750 -Os -pipe -fno-strict-
aliasing -mpowerpc-gfxopt"

I was very surprised to find that this resulted in a usable build of
mplayer on this ol' G3 @ 400MHz. I can watch a 624x352 XviD without
altivec. Only catches are that cpu usage is at 100% and there is the
occasional dropped frame, and that the default audio out (oss) makes
human voices scratchy and unlistenable. -ao alsa fixes that right up
though.

In any event, here's how I did it for those of you playing along at
home:

#NOTE: apt will pull in some prerequisites - keep track of these if you want to 
delete them later
sudo apt-get install libx264-dev libxvidcore4-dev libfaac-dev libasound2-dev 
libxv-dev libfontconfig1-dev
cd /tmp
sudo apt-get source mplayer
export CXXFLAGS="" ; export CFLAGS="" 
./configure --enable-largefiles --disable-tv --disable-pvr --disable-tv-v4l1 
--disable-tv-v4l2 \
--disable-tv-bsdbt848 --disable-unrarlib --disable-inet6 --disable-ftp
make && sudo make install

I also had a successful build with these CFLAGS, but haven't compared the two 
for performance or anything like that:
export CXXFLAGS="-mcpu=740 -Os -pipe -fno-strict-aliasing -mpowerpc-gfxopt" ;
export CFLAGS="-mcpu=740 -Os -pipe -fno-strict-aliasing -mpowerpc-gfxopt" ;

It takes between 20 minutes (with -Os) and 30 (with -O4 as mplayer's
config script defaults to) to build the binary. You'll almost certainly
want to add -maltivec if you are compiling on a G4.

I'm sure that even on my system there is more to tune, but I'm not
running gentoo here, so I'm happy for the moment ;-)

Good luck!

-- 
mplayer ppc crash due to incorrect use of fsqrt
https://bugs.launchpad.net/bugs/104630
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