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LILO as shipped with RH 6.1 (and possibly 6.0) reports that a newly built kernel is too big. This does however not happen if you use the version of lilo that came with RH 5.2. I sort of found this out while building a monolithic kernel on an updated RH6.1 box with LILO 0.21. The kernel was about 480 kB. After a bit of thinking I downgraded to LILO 0.20 and then it worked again.
Use 'make bzImage' instead of 'make zImage'. That should solve the problem.
Yes, make bzImage might work (although if I recall the events correctly it did not allways work). The thing that bothers me is that LILO 0.20 works where 0.21 does not.
Assigned to dledford
This is because lilo-0.21 loads the kernel slightly differently, because it works around some problems with some newer/strange BIOSes ; hence it has a little less memory for zImage use.