Forum 
Author
Quote
Fatal: Setup length exceeds 31 maximum; kernel setup will overwrite boot loader
Since I was pretty certain that it wasn't a configuration error, I thought it to be a limitation of LILO and kernel sizes, but that wasn't the case.After an upgrade to GRUB and I managed to boot my system again, e2fsck went ape when checking my /boot, discovering all sorts of cross-linked blocks and such. This turned out to be the cause of all the LILO mayhem.
So my suggestion to you when encountering this problem: before doing anything else, first do an fsck. It might help out.
Logged
