I don't think I've seen this one before . . . I have /boot mounted on the first partition, a single cylinder. /vmlinux is a symbolic link to /boot/vmlinux-2.0.33. Rather than following the link, "make zImage zlilo" is placing a vmlinuz in /, undoing the old link, and crossing the 1023 cylinder boundry. I'm pretty sure that this didn't used to happen, since I didn't used to have a problem :)
rick -- These opinions will not be those of ISU until it pays my retainer.