}
        bi = conf->retry_read_aligned_list;
        if(bi) {
-               conf->retry_read_aligned = bi->bi_next;
+               conf->retry_read_aligned_list = bi->bi_next;
                bi->bi_next = NULL;
                bi->bi_phys_segments = 1; /* biased count of active stripes */
                bi->bi_hw_segments = 0; /* count of processed stripes */
        return 0;
 }
 
+static int bio_fits_rdev(struct bio *bi)
+{
+       request_queue_t *q = bdev_get_queue(bi->bi_bdev);
+
+       if ((bi->bi_size>>9) > q->max_sectors)
+               return 0;
+       blk_recount_segments(q, bi);
+       if (bi->bi_phys_segments > q->max_phys_segments ||
+           bi->bi_hw_segments > q->max_hw_segments)
+               return 0;
+
+       if (q->merge_bvec_fn)
+               /* it's too hard to apply the merge_bvec_fn at this stage,
+                * just just give up
+                */
+               return 0;
+
+       return 1;
+}
+
+
 static int chunk_aligned_read(request_queue_t *q, struct bio * raid_bio)
 {
        mddev_t *mddev = q->queuedata;
                align_bi->bi_flags &= ~(1 << BIO_SEG_VALID);
                align_bi->bi_sector += rdev->data_offset;
 
+               if (!bio_fits_rdev(align_bi)) {
+                       /* too big in some way */
+                       bio_put(align_bi);
+                       rdev_dec_pending(rdev, mddev);
+                       return 0;
+               }
+
                spin_lock_irq(&conf->device_lock);
                wait_event_lock_irq(conf->wait_for_stripe,
                                    conf->quiesce == 0,
        last_sector = raid_bio->bi_sector + (raid_bio->bi_size>>9);
 
        for (; logical_sector < last_sector;
-            logical_sector += STRIPE_SECTORS, scnt++) {
+            logical_sector += STRIPE_SECTORS,
+                    sector += STRIPE_SECTORS,
+                    scnt++) {
 
                if (scnt < raid_bio->bi_hw_segments)
                        /* already done this stripe */
                }
 
                set_bit(R5_ReadError, &sh->dev[dd_idx].flags);
-               add_stripe_bio(sh, raid_bio, dd_idx, 0);
+               if (!add_stripe_bio(sh, raid_bio, dd_idx, 0)) {
+                       release_stripe(sh);
+                       raid_bio->bi_hw_segments = scnt;
+                       conf->retry_read_aligned = raid_bio;
+                       return handled;
+               }
+
                handle_stripe(sh, NULL);
                release_stripe(sh);
                handled++;