For versions after Hudson v1.377 until about Jenkins v1.400, There were several issues with FilePath.copyRecursiveTo and remoting.
They are now fixed. Open again if not.

Even I am seeing this issue more often.

I am using Jenkins Version 1.406
hudson.util.IOException2: java.io.IOException: request to write '8192' bytes exceeds size in header of '26832325' bytes for entry 'output/ri_console_log.txt'
at hudson.FilePath.copyRecursiveTo(FilePath.java:1546)
at hudson.tasks.ArtifactArchiver.perform(ArtifactArchiver.java:117)
at hudson.tasks.BuildStepMonitor$1.perform(BuildStepMonitor.java:19)
at hudson.model.AbstractBuild$AbstractRunner.perform(AbstractBuild.java:649)
at hudson.model.AbstractBuild$AbstractRunner.performAllBuildSteps(AbstractBuild.java:625)
at hudson.model.AbstractBuild$AbstractRunner.performAllBuildSteps(AbstractBuild.java:603)
at hudson.model.Build$RunnerImpl.post2(Build.java:161)
at hudson.model.AbstractBuild$AbstractRunner.post(AbstractBuild.java:572)
at hudson.model.Run.run(Run.java:1386)
at hudson.model.FreeStyleBuild.run(FreeStyleBuild.java:46)
at hudson.model.ResourceController.execute(ResourceController.java:88)
at hudson.model.Executor.run(Executor.java:145)
Caused by: java.util.concurrent.ExecutionException: java.io.IOException: request to write '8192' bytes exceeds size in header of '26832325' bytes for entry 'output/ri_console_log.txt'
at hudson.remoting.Channel$2.adapt(Channel.java:676)
at hudson.remoting.Channel$2.adapt(Channel.java:671)
at hudson.remoting.FutureAdapter.get(FutureAdapter.java:55)
at hudson.FilePath.copyRecursiveTo(FilePath.java:1544)
... 11 more
Caused by: java.io.IOException: request to write '8192' bytes exceeds size in header of '26832325' bytes for entry 'output/ri_console_log.txt'
at hudson.org.apache.tools.tar.TarOutputStream.write(TarOutputStream.java:284)
at hudson.util.io.TarArchiver.visit(TarArchiver.java:103)
at hudson.util.DirScanner$Glob.scan(DirScanner.java:104)
at hudson.FilePath.writeToTar(FilePath.java:1582)
at hudson.FilePath.access$900(FilePath.java:163)
at hudson.FilePath$33.invoke(FilePath.java:1523)
at hudson.FilePath$33.invoke(FilePath.java:1520)
at hudson.FilePath$FileCallableWrapper.call(FilePath.java:1944)
at hudson.remoting.UserRequest.perform(UserRequest.java:118)
at hudson.remoting.UserRequest.perform(UserRequest.java:48)
at hudson.remoting.Request$2.run(Request.java:270)
at java.util.concurrent.Executors$RunnableAdapter.call(Unknown Source)
at java.util.concurrent.FutureTask$Sync.innerRun(Unknown Source)
at java.util.concurrent.FutureTask.run(Unknown Source)
at java.util.concurrent.ThreadPoolExecutor$Worker.runTask(Unknown Source)
at java.util.concurrent.ThreadPoolExecutor$Worker.run(Unknown Source)
at java.lang.Thread.run(Unknown Source)

Please tell if there is any workaround or do I need to update Jenkins version?

I am still seeing this in Jenkins 1.500 on Scientific Linux:

[ ERROR ] Execution stopped by user.
ERROR: Failed to archive artifacts: out/,out/screenshots/
hudson.util.IOException2: java.io.IOException: request to write '8192' bytes exceeds size in header of '110592' bytes for entry 'out/output.xml'
at hudson.FilePath.copyRecursiveTo(FilePath.java:1903)
at hudson.tasks.ArtifactArchiver.perform(ArtifactArchiver.java:116)
at hudson.tasks.BuildStepMonitor$1.perform(BuildStepMonitor.java:19)
at hudson.model.AbstractBuild$AbstractBuildExecution.perform(AbstractBuild.java:810)
at hudson.model.AbstractBuild$AbstractBuildExecution.performAllBuildSteps(AbstractBuild.java:785)
at hudson.model.Build$BuildExecution.post2(Build.java:183)
at hudson.model.AbstractBuild$AbstractBuildExecution.post(AbstractBuild.java:732)
at hudson.model.Run.execute(Run.java:1582)
at hudson.model.FreeStyleBuild.run(FreeStyleBuild.java:46)
at hudson.model.ResourceController.execute(ResourceController.java:88)
at hudson.model.Executor.run(Executor.java:236)
Caused by: java.util.concurrent.ExecutionException: java.io.IOException: request to write '8192' bytes exceeds size in header of '110592' bytes for entry 'out/output.xml'
at hudson.remoting.Channel$4.adapt(Channel.java:705)
at hudson.remoting.Channel$4.adapt(Channel.java:700)
at hudson.remoting.FutureAdapter.get(FutureAdapter.java:55)
at hudson.FilePath.copyRecursiveTo(FilePath.java:1901)
... 10 more
Caused by: java.io.IOException: request to write '8192' bytes exceeds size in header of '110592' bytes for entry 'out/output.xml'
at hudson.org.apache.tools.tar.TarOutputStream.write(TarOutputStream.java:284)
at hudson.util.io.TarArchiver.visit(TarArchiver.java:115)
at hudson.util.DirScanner$Glob.scan(DirScanner.java:133)
at hudson.FilePath.writeToTar(FilePath.java:1939)
at hudson.FilePath.access$1000(FilePath.java:168)
at hudson.FilePath$36.invoke(FilePath.java:1880)
at hudson.FilePath$36.invoke(FilePath.java:1876)
at hudson.FilePath$FileCallableWrapper.call(FilePath.java:2348)
at hudson.remoting.UserRequest.perform(UserRequest.java:118)
at hudson.remoting.UserRequest.perform(UserRequest.java:48)
at hudson.remoting.Request$2.run(Request.java:326)
at hudson.remoting.InterceptingExecutorService$1.call(InterceptingExecutorService.java:72)
at java.util.concurrent.FutureTask$Sync.innerRun(FutureTask.java:303)
at java.util.concurrent.FutureTask.run(FutureTask.java:138)
at java.util.concurrent.ThreadPoolExecutor$Worker.runTask(ThreadPoolExecutor.java:886)
at java.util.concurrent.ThreadPoolExecutor$Worker.run(ThreadPoolExecutor.java:908)
at java.lang.Thread.run(Thread.java:680)
Finished: ABORTED

As for "output.xml": We recently switched on debug logging for our tests, so the "output.xml" in question is now way larger than before, maybe large files trigger this defect.

Thanks for looking into this!

I confirm the issue still occurs on 1.508:

hudson.util.IOException2: java.io.IOException: request to write '8192' bytes exceeds size in header of '27566743' bytes for entry 'logs/error.log'
at hudson.FilePath.copyRecursiveTo(FilePath.java:1903)
at com.michelin.cio.hudson.plugins.copytoslave.CopyToMasterNotifier.perform(CopyToMasterNotifier.java:93)
at hudson.tasks.BuildStepMonitor$3.perform(BuildStepMonitor.java:36)
at hudson.model.AbstractBuild$AbstractBuildExecution.perform(AbstractBuild.java:798)
at hudson.model.AbstractBuild$AbstractBuildExecution.performAllBuildSteps(AbstractBuild.java:770)
at hudson.model.Build$BuildExecution.cleanUp(Build.java:192)
at hudson.model.Run.execute(Run.java:1620)
at hudson.matrix.MatrixRun.run(MatrixRun.java:146)
at hudson.model.ResourceController.execute(ResourceController.java:88)
at hudson.model.Executor.run(Executor.java:237)
Caused by: java.util.concurrent.ExecutionException: java.io.IOException: request to write '8192' bytes exceeds size in header of '27566743' bytes for entry 'logs/error.log'
at hudson.remoting.Channel$4.adapt(Channel.java:705)
at hudson.remoting.Channel$4.adapt(Channel.java:700)
at hudson.remoting.FutureAdapter.get(FutureAdapter.java:55)
at hudson.FilePath.copyRecursiveTo(FilePath.java:1901)
... 9 more
Caused by: java.io.IOException: request to write '8192' bytes exceeds size in header of '27566743' bytes for entry 'logs/error.log'
at hudson.org.apache.tools.tar.TarOutputStream.write(TarOutputStream.java:284)
at hudson.util.io.TarArchiver.visit(TarArchiver.java:115)
at hudson.util.DirScanner$Glob.scan(DirScanner.java:133)
at hudson.FilePath.writeToTar(FilePath.java:1939)
at hudson.FilePath.access$1000(FilePath.java:168)
at hudson.FilePath$36.invoke(FilePath.java:1880)
at hudson.FilePath$36.invoke(FilePath.java:1876)
at hudson.FilePath$FileCallableWrapper.call(FilePath.java:2348)
at hudson.remoting.UserRequest.perform(UserRequest.java:118)
at hudson.remoting.UserRequest.perform(UserRequest.java:48)
at hudson.remoting.Request$2.run(Request.java:326)
at hudson.remoting.InterceptingExecutorService$1.call(InterceptingExecutorService.java:72)
at java.util.concurrent.FutureTask$Sync.innerRun(FutureTask.java:303)
at java.util.concurrent.FutureTask.run(FutureTask.java:138)
at java.util.concurrent.ThreadPoolExecutor$Worker.runTask(ThreadPoolExecutor.java:886)
at java.util.concurrent.ThreadPoolExecutor$Worker.run(ThreadPoolExecutor.java:908)
at java.lang.Thread.run(Thread.java:662)

Can someone please have a look at this issue and give us some advice?

Is there any way to help debugging it?

Ie. could a possible reason be that the file is being read/write (by another process) during the archive process?

I also see this issue on 1.514:

Archiving artifacts
ERROR: Failed to archive artifacts: target/test.log
hudson.util.IOException2: java.io.IOException: request to write '8192' bytes exceeds size in header of '9830918' bytes for entry 'target/test.log'
	at hudson.FilePath.copyRecursiveTo(FilePath.java:1942)
	at hudson.tasks.ArtifactArchiver.perform(ArtifactArchiver.java:137)
	at hudson.tasks.BuildStepMonitor$1.perform(BuildStepMonitor.java:19)
	at hudson.model.AbstractBuild$AbstractBuildExecution.perform(AbstractBuild.java:804)
	at hudson.model.AbstractBuild$AbstractBuildExecution.performAllBuildSteps(AbstractBuild.java:776)
	at hudson.model.Build$BuildExecution.post2(Build.java:183)
	at hudson.model.AbstractBuild$AbstractBuildExecution.post(AbstractBuild.java:726)
	at hudson.model.Run.execute(Run.java:1600)
	at hudson.matrix.MatrixRun.run(MatrixRun.java:146)
	at hudson.model.ResourceController.execute(ResourceController.java:88)
	at hudson.model.Executor.run(Executor.java:241)
Caused by: java.util.concurrent.ExecutionException: java.io.IOException: request to write '8192' bytes exceeds size in header of '9830918' bytes for entry 'target/test.log'
	at hudson.remoting.Channel$4.adapt(Channel.java:705)
	at hudson.remoting.Channel$4.adapt(Channel.java:700)
	at hudson.remoting.FutureAdapter.get(FutureAdapter.java:55)
	at hudson.FilePath.copyRecursiveTo(FilePath.java:1940)
	... 10 more
Caused by: java.io.IOException: request to write '8192' bytes exceeds size in header of '9830918' bytes for entry 'target/test.log'
	at hudson.org.apache.tools.tar.TarOutputStream.write(TarOutputStream.java:284)
	at hudson.util.io.TarArchiver.visit(TarArchiver.java:115)
	at hudson.util.DirScanner$Glob.scan(DirScanner.java:133)
	at hudson.FilePath.writeToTar(FilePath.java:1978)
	at hudson.FilePath.access$1000(FilePath.java:168)
	at hudson.FilePath$36.invoke(FilePath.java:1919)
	at hudson.FilePath$36.invoke(FilePath.java:1915)
	at hudson.FilePath$FileCallableWrapper.call(FilePath.java:2387)
	at hudson.remoting.UserRequest.perform(UserRequest.java:118)
	at hudson.remoting.UserRequest.perform(UserRequest.java:48)
	at hudson.remoting.Request$2.run(Request.java:326)
	at hudson.remoting.InterceptingExecutorService$1.call(InterceptingExecutorService.java:72)
	at java.util.concurrent.FutureTask$Sync.innerRun(FutureTask.java:334)
	at java.util.concurrent.FutureTask.run(FutureTask.java:166)
	at java.util.concurrent.ThreadPoolExecutor.runWorker(ThreadPoolExecutor.java:1145)
	at java.util.concurrent.ThreadPoolExecutor$Worker.run(ThreadPoolExecutor.java:615)
	at java.lang.Thread.run(Thread.java:724)

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Just saw this error as well on Jenkins 1.510 running on Windows Server 2003 master & slave. Job had run on the slave. Have never seen this before.

Archiving artifacts
ERROR: Failed to archive artifacts: win32_x86/release/logs/Build/*, win32_x86/release/logs/DataServices/*, win64_x64/release/logs/Build/*, win64_x64/release/logs/DataServices/*
hudson.util.IOException2: java.io.IOException: request to write '934' bytes exceeds size in header of '6570859' bytes for entry 'win64_x64/release/logs/DataServices/rebuild_release_shellframe_Intl.log'
	at hudson.FilePath.copyRecursiveTo(FilePath.java:1942)
	at hudson.tasks.ArtifactArchiver.perform(ArtifactArchiver.java:133)
	at hudson.tasks.BuildStepMonitor$1.perform(BuildStepMonitor.java:19)
	at hudson.model.AbstractBuild$AbstractBuildExecution.perform(AbstractBuild.java:798)
	at hudson.model.AbstractBuild$AbstractBuildExecution.performAllBuildSteps(AbstractBuild.java:770)
	at hudson.model.Build$BuildExecution.post2(Build.java:183)
	at hudson.model.AbstractBuild$AbstractBuildExecution.post(AbstractBuild.java:720)
	at hudson.model.Run.execute(Run.java:1600)
	at hudson.model.FreeStyleBuild.run(FreeStyleBuild.java:46)
	at hudson.model.ResourceController.execute(ResourceController.java:88)
	at hudson.model.Executor.run(Executor.java:237)
Caused by: java.util.concurrent.ExecutionException: java.io.IOException: request to write '934' bytes exceeds size in header of '6570859' bytes for entry 'win64_x64/release/logs/DataServices/rebuild_release_shellframe_Intl.log'
	at hudson.remoting.Channel$4.adapt(Channel.java:705)
	at hudson.remoting.Channel$4.adapt(Channel.java:700)
	at hudson.remoting.FutureAdapter.get(FutureAdapter.java:55)
	at hudson.FilePath.copyRecursiveTo(FilePath.java:1940)
	... 10 more
Caused by: java.io.IOException: request to write '934' bytes exceeds size in header of '6570859' bytes for entry 'win64_x64/release/logs/DataServices/rebuild_release_shellframe_Intl.log'
	at hudson.org.apache.tools.tar.TarOutputStream.write(TarOutputStream.java:284)
	at hudson.util.io.TarArchiver.visit(TarArchiver.java:115)
	at hudson.util.DirScanner$Glob.scan(DirScanner.java:133)
	at hudson.FilePath.writeToTar(FilePath.java:1978)
	at hudson.FilePath.access$1000(FilePath.java:168)
	at hudson.FilePath$36.invoke(FilePath.java:1919)
	at hudson.FilePath$36.invoke(FilePath.java:1915)
	at hudson.FilePath$FileCallableWrapper.call(FilePath.java:2387)
	at hudson.remoting.UserRequest.perform(UserRequest.java:118)
	at hudson.remoting.UserRequest.perform(UserRequest.java:48)
	at hudson.remoting.Request$2.run(Request.java:326)
	at hudson.remoting.InterceptingExecutorService$1.call(InterceptingExecutorService.java:72)
	at java.util.concurrent.FutureTask$Sync.innerRun(Unknown Source)
	at java.util.concurrent.FutureTask.run(Unknown Source)
	at java.util.concurrent.ThreadPoolExecutor$Worker.runTask(Unknown Source)
	at java.util.concurrent.ThreadPoolExecutor$Worker.run(Unknown Source)
	at hudson.remoting.Engine$1$1.run(Engine.java:58)
	at java.lang.Thread.run(Unknown Source)
Build step 'Archive the artifacts' changed build result to FAILURE

We're also seeing it on Jenkins 1.466.2 running on Windows.

Also seeing this with Jenkins 1.537.

Am seeing this on 1.566

I am seeing this issue in 1.555 :

11:12:54 ERROR: Failed to archive artifacts: *.log
11:12:54 java.io.IOException: java.util.concurrent.ExecutionException: java.io.IOException: request to write '8192' bytes exceeds size in header of '26982170' bytes for entry 'output.log'
11:12:54 	at hudson.FilePath.copyRecursiveTo(FilePath.java:2017)
11:12:54 	at jenkins.model.StandardArtifactManager.archive(StandardArtifactManager.java:57)
11:12:54 	at hudson.tasks.ArtifactArchiver.perform(ArtifactArchiver.java:140)
11:12:54 	at hudson.tasks.BuildStepMonitor$1.perform(BuildStepMonitor.java:20)
11:12:54 	at hudson.model.AbstractBuild$AbstractBuildExecution.perform(AbstractBuild.java:804)
11:12:54 	at hudson.model.AbstractBuild$AbstractBuildExecution.performAllBuildSteps(AbstractBuild.java:776)
11:12:54 	at hudson.model.Build$BuildExecution.post2(Build.java:183)
11:12:54 	at hudson.model.AbstractBuild$AbstractBuildExecution.post(AbstractBuild.java:725)
11:12:54 	at hudson.model.Run.execute(Run.java:1701)
11:12:54 	at hudson.model.FreeStyleBuild.run(FreeStyleBuild.java:43)
11:12:54 	at hudson.model.ResourceController.execute(ResourceController.java:88)
11:12:54 	at hudson.model.Executor.run(Executor.java:231)
11:12:54 Caused by: java.util.concurrent.ExecutionException: java.io.IOException: request to write '8192' bytes exceeds size in header of '26982170' bytes for entry 'output.log'
11:12:54 	at hudson.remoting.Channel$3.adapt(Channel.java:755)
11:12:54 	at hudson.remoting.Channel$3.adapt(Channel.java:750)
11:12:54 	at hudson.remoting.FutureAdapter.get(FutureAdapter.java:55)
11:12:54 	at hudson.FilePath.copyRecursiveTo(FilePath.java:2015)
11:12:54 	... 11 more
11:12:54 Caused by: java.io.IOException: request to write '8192' bytes exceeds size in header of '26982170' bytes for entry 'output.log'
11:12:54 	at hudson.org.apache.tools.tar.TarOutputStream.write(TarOutputStream.java:284)
11:12:54 	at hudson.util.io.TarArchiver.visit(TarArchiver.java:114)
11:12:54 	at hudson.util.DirScanner.scanSingle(DirScanner.java:49)
11:12:54 	at hudson.FilePath$ExplicitlySpecifiedDirScanner.scan(FilePath.java:2541)
11:12:54 	at hudson.FilePath.writeToTar(FilePath.java:2053)
11:12:54 	at hudson.FilePath.access$1000(FilePath.java:172)
11:12:54 	at hudson.FilePath$41.invoke(FilePath.java:1994)
11:12:54 	at hudson.FilePath$41.invoke(FilePath.java:1990)
11:12:54 	at hudson.FilePath$FileCallableWrapper.call(FilePath.java:2462)
11:12:54 	at hudson.remoting.UserRequest.perform(UserRequest.java:118)
11:12:54 	at hudson.remoting.UserRequest.perform(UserRequest.java:48)
11:12:54 	at hudson.remoting.Request$2.run(Request.java:328)
11:12:54 	at hudson.remoting.InterceptingExecutorService$1.call(InterceptingExecutorService.java:72)
11:12:54 	at java.util.concurrent.FutureTask$Sync.innerRun(FutureTask.java:303)
11:12:54 	at java.util.concurrent.FutureTask.run(FutureTask.java:138)
11:12:54 	at java.util.concurrent.ThreadPoolExecutor$Worker.runTask(ThreadPoolExecutor.java:886)
11:12:54 	at java.util.concurrent.ThreadPoolExecutor$Worker.run(ThreadPoolExecutor.java:908)
11:12:54 	at java.lang.Thread.run(Thread.java:662)
11:12:54 Build step 'Archive the artifacts' changed build result to FAILURE

I am seeing this in 1.571:

ERROR: Failed to archive artifacts: *.log
java.io.IOException: java.io.IOException: Failed to extract /var/lib/jenkins/workspace/OneOneOne/transfer of 6 files
	at hudson.FilePath.readFromTar(FilePath.java:2119)
	at hudson.FilePath.copyRecursiveTo(FilePath.java:2031)
	at jenkins.model.StandardArtifactManager.archive(StandardArtifactManager.java:61)
	at hudson.tasks.ArtifactArchiver.perform(ArtifactArchiver.java:183)
	at hudson.tasks.BuildStepMonitor$1.perform(BuildStepMonitor.java:20)
	at hudson.model.AbstractBuild$AbstractBuildExecution.perform(AbstractBuild.java:772)
	at hudson.model.AbstractBuild$AbstractBuildExecution.performAllBuildSteps(AbstractBuild.java:736)
	at hudson.model.Build$BuildExecution.post2(Build.java:183)
	at hudson.model.AbstractBuild$AbstractBuildExecution.post(AbstractBuild.java:685)
	at hudson.model.Run.execute(Run.java:1757)
	at hudson.model.FreeStyleBuild.run(FreeStyleBuild.java:43)
	at hudson.model.ResourceController.execute(ResourceController.java:88)
	at hudson.model.Executor.run(Executor.java:234)
Caused by: java.io.IOException: unexpected EOF with 1921 bytes unread
	at hudson.org.apache.tools.tar.TarInputStream.read(TarInputStream.java:349)
	at java.io.FilterInputStream.read(FilterInputStream.java:90)
	at org.apache.commons.io.IOUtils.copyLarge(IOUtils.java:1792)
	at org.apache.commons.io.IOUtils.copyLarge(IOUtils.java:1769)
	at org.apache.commons.io.IOUtils.copy(IOUtils.java:1744)
	at hudson.util.IOUtils.copy(IOUtils.java:40)
	at hudson.FilePath.readFromTar(FilePath.java:2109)
	... 12 more

	at hudson.FilePath.copyRecursiveTo(FilePath.java:2038)
	at jenkins.model.StandardArtifactManager.archive(StandardArtifactManager.java:61)
	at hudson.tasks.ArtifactArchiver.perform(ArtifactArchiver.java:183)
	at hudson.tasks.BuildStepMonitor$1.perform(BuildStepMonitor.java:20)
	at hudson.model.AbstractBuild$AbstractBuildExecution.perform(AbstractBuild.java:772)
	at hudson.model.AbstractBuild$AbstractBuildExecution.performAllBuildSteps(AbstractBuild.java:736)
	at hudson.model.Build$BuildExecution.post2(Build.java:183)
	at hudson.model.AbstractBuild$AbstractBuildExecution.post(AbstractBuild.java:685)
	at hudson.model.Run.execute(Run.java:1757)
	at hudson.model.FreeStyleBuild.run(FreeStyleBuild.java:43)
	at hudson.model.ResourceController.execute(ResourceController.java:88)
	at hudson.model.Executor.run(Executor.java:234)
Caused by: java.util.concurrent.ExecutionException: java.io.IOException: request to write '4053' bytes exceeds size in header of '85889' bytes for entry 'models.log'
	at hudson.remoting.Channel$3.adapt(Channel.java:772)
	at hudson.remoting.Channel$3.adapt(Channel.java:767)
	at hudson.remoting.FutureAdapter.get(FutureAdapter.java:59)
	at hudson.FilePath.copyRecursiveTo(FilePath.java:2034)
	... 11 more
Caused by: java.io.IOException: request to write '4053' bytes exceeds size in header of '85889' bytes for entry 'models.log'
	at hudson.org.apache.tools.tar.TarOutputStream.write(TarOutputStream.java:284)
	at hudson.util.io.TarArchiver.visit(TarArchiver.java:114)
	at hudson.util.DirScanner.scanSingle(DirScanner.java:49)
	at hudson.FilePath$ExplicitlySpecifiedDirScanner.scan(FilePath.java:2571)
	at hudson.FilePath.writeToTar(FilePath.java:2083)
	at hudson.FilePath.access$1000(FilePath.java:180)
	at hudson.FilePath$41.invoke(FilePath.java:2024)
	at hudson.FilePath$41.invoke(FilePath.java:2020)
	at hudson.FilePath$FileCallableWrapper.call(FilePath.java:2492)
	at hudson.remoting.UserRequest.perform(UserRequest.java:118)
	at hudson.remoting.UserRequest.perform(UserRequest.java:48)
	at hudson.remoting.Request$2.run(Request.java:328)
	at hudson.remoting.InterceptingExecutorService$1.call(InterceptingExecutorService.java:72)
	at java.util.concurrent.FutureTask$Sync.innerRun(FutureTask.java:334)
	at java.util.concurrent.FutureTask.run(FutureTask.java:166)
	at java.util.concurrent.ThreadPoolExecutor.runWorker(ThreadPoolExecutor.java:1146)
	at java.util.concurrent.ThreadPoolExecutor$Worker.run(ThreadPoolExecutor.java:615)
	at hudson.remoting.Engine$1$1.run(Engine.java:63)
	at java.lang.Thread.run(Thread.java:701)
Build step 'Archive the artifacts' changed build result to FAILURE

We are having this issue as well; we are running Jenkins 1.580.

Also see this in 1.582

11:33:56 ERROR: Failed to archive artifacts: _test/**
11:33:56 java.io.IOException: java.util.concurrent.ExecutionException: java.io.IOException: request to write '1757' bytes exceeds size in header of '132283' bytes for entry '_test/output.log'
11:33:56 at hudson.FilePath.copyRecursiveTo(FilePath.java:2039)
11:33:56 at jenkins.model.StandardArtifactManager.archive(StandardArtifactManager.java:61)
11:33:56 at hudson.tasks.ArtifactArchiver.perform(ArtifactArchiver.java:217)
11:33:56 at hudson.tasks.BuildStepCompatibilityLayer.perform(BuildStepCompatibilityLayer.java:74)
11:33:56 at hudson.tasks.BuildStepMonitor$1.perform(BuildStepMonitor.java:20)
11:33:56 at hudson.model.AbstractBuild$AbstractBuildExecution.perform(AbstractBuild.java:770)
11:33:56 at hudson.model.AbstractBuild$AbstractBuildExecution.performAllBuildSteps(AbstractBuild.java:734)
11:33:56 at hudson.model.Build$BuildExecution.post2(Build.java:183)
11:33:56 at hudson.model.AbstractBuild$AbstractBuildExecution.post(AbstractBuild.java:683)
11:33:56 at hudson.model.Run.execute(Run.java:1770)
11:33:56 at hudson.model.FreeStyleBuild.run(FreeStyleBuild.java:43)
11:33:56 at hudson.model.ResourceController.execute(ResourceController.java:89)
11:33:56 at hudson.model.Executor.run(Executor.java:240)
11:33:56 Caused by: java.util.concurrent.ExecutionException: java.io.IOException: request to write '1757' bytes exceeds size in header of '132283' bytes for entry '_test/output.log'
11:33:56 at hudson.remoting.Channel$3.adapt(Channel.java:772)
11:33:56 at hudson.remoting.Channel$3.adapt(Channel.java:767)
11:33:56 at hudson.remoting.FutureAdapter.get(FutureAdapter.java:55)
11:33:56 at hudson.FilePath.copyRecursiveTo(FilePath.java:2037)
11:33:56 ... 12 more

Am also experiencing similar, in 1.596.2

17:13:41 GMT+01:00 Archiving artifacts
17:13:43 GMT+01:00 ERROR: Failed to archive artifacts: LOGS/,target/**/LOGS/,target/robotframework/
17:13:43 GMT+01:00 java.io.IOException: java.util.concurrent.ExecutionException: java.io.IOException: request to write '3085' bytes exceeds size in header of '2581956' bytes for entry 'target/path/to/file_20_05_2015.log'
17:13:43 GMT+01:00 	at hudson.FilePath.copyRecursiveTo(FilePath.java:2213)
17:13:43 GMT+01:00 	at jenkins.model.StandardArtifactManager.archive(StandardArtifactManager.java:61)
17:13:43 GMT+01:00 	at hudson.tasks.ArtifactArchiver.perform(ArtifactArchiver.java:218)
17:13:43 GMT+01:00 	at hudson.tasks.BuildStepCompatibilityLayer.perform(BuildStepCompatibilityLayer.java:74)
17:13:43 GMT+01:00 	at org.jenkins_ci.plugins.flexible_publish.builder.FailFastBuilder.perform(FailFastBuilder.java:102)
17:13:43 GMT+01:00 	at org.jenkins_ci.plugins.run_condition.BuildStepRunner$2.run(BuildStepRunner.java:110)
17:13:43 GMT+01:00 	at org.jenkins_ci.plugins.run_condition.BuildStepRunner$Fail.conditionalRun(BuildStepRunner.java:154)
17:13:43 GMT+01:00 	at org.jenkins_ci.plugins.run_condition.BuildStepRunner.perform(BuildStepRunner.java:105)
17:13:43 GMT+01:00 	at org.jenkins_ci.plugins.flexible_publish.strategy.FailFastExecutionStrategy.perform(FailFastExecutionStrategy.java:63)
17:13:43 GMT+01:00 	at org.jenkins_ci.plugins.flexible_publish.ConditionalPublisher.perform(ConditionalPublisher.java:206)
17:13:43 GMT+01:00 	at org.jenkins_ci.plugins.flexible_publish.FlexiblePublisher.perform(FlexiblePublisher.java:124)
17:13:43 GMT+01:00 	at hudson.tasks.BuildStepMonitor$1.perform(BuildStepMonitor.java:20)
17:13:43 GMT+01:00 	at hudson.model.AbstractBuild$AbstractBuildExecution.perform(AbstractBuild.java:770)
17:13:43 GMT+01:00 	at hudson.model.AbstractBuild$AbstractBuildExecution.performAllBuildSteps(AbstractBuild.java:734)
17:13:43 GMT+01:00 	at hudson.model.Build$BuildExecution.post2(Build.java:183)
17:13:43 GMT+01:00 	at hudson.model.AbstractBuild$AbstractBuildExecution.post(AbstractBuild.java:683)
17:13:43 GMT+01:00 	at hudson.model.Run.execute(Run.java:1784)
17:13:43 GMT+01:00 	at hudson.model.FreeStyleBuild.run(FreeStyleBuild.java:43)
17:13:43 GMT+01:00 	at hudson.model.ResourceController.execute(ResourceController.java:89)
17:13:43 GMT+01:00 	at hudson.model.Executor.run(Executor.java:240)
17:13:43 GMT+01:00 Caused by: java.util.concurrent.ExecutionException: java.io.IOException: request to write '3085' bytes exceeds size in header of '2581956' bytes for entry 'target/path/to/file_20_05_2015.log'
17:13:43 GMT+01:00 	at hudson.remoting.Channel$3.adapt(Channel.java:784)
17:13:43 GMT+01:00 	at hudson.remoting.Channel$3.adapt(Channel.java:779)
17:13:43 GMT+01:00 	at hudson.remoting.FutureAdapter.get(FutureAdapter.java:55)
17:13:43 GMT+01:00 	at hudson.FilePath.copyRecursiveTo(FilePath.java:2211)
17:13:43 GMT+01:00 	... 19 more
17:13:43 GMT+01:00 Caused by: java.io.IOException: request to write '3085' bytes exceeds size in header of '2581956' bytes for entry 'target/path/to/file_20_05_2015.log'
17:13:43 GMT+01:00 	at hudson.org.apache.tools.tar.TarOutputStream.write(TarOutputStream.java:284)
17:13:43 GMT+01:00 	at hudson.util.io.TarArchiver.visit(TarArchiver.java:114)
17:13:43 GMT+01:00 	at hudson.util.DirScanner.scanSingle(DirScanner.java:49)
17:13:43 GMT+01:00 	at hudson.FilePath$ExplicitlySpecifiedDirScanner.scan(FilePath.java:2764)
17:13:43 GMT+01:00 	at hudson.FilePath.writeToTar(FilePath.java:2249)
17:13:43 GMT+01:00 	at hudson.FilePath.access$2100(FilePath.java:191)
17:13:43 GMT+01:00 	at hudson.FilePath$45.invoke(FilePath.java:2190)
17:13:43 GMT+01:00 	at hudson.FilePath$45.invoke(FilePath.java:2186)
17:13:43 GMT+01:00 	at hudson.FilePath$FileCallableWrapper.call(FilePath.java:2677)
17:13:43 GMT+01:00 	at hudson.remoting.UserRequest.perform(UserRequest.java:121)
17:13:43 GMT+01:00 	at hudson.remoting.UserRequest.perform(UserRequest.java:49)
17:13:43 GMT+01:00 	at hudson.remoting.Request$2.run(Request.java:324)
17:13:43 GMT+01:00 	at hudson.remoting.InterceptingExecutorService$1.call(InterceptingExecutorService.java:68)
17:13:43 GMT+01:00 	at java.util.concurrent.FutureTask.run(Unknown Source)
17:13:43 GMT+01:00 	at java.util.concurrent.ThreadPoolExecutor.runWorker(Unknown Source)
17:13:43 GMT+01:00 	at java.util.concurrent.ThreadPoolExecutor$Worker.run(Unknown Source)
17:13:43 GMT+01:00 	at hudson.remoting.Engine$1$1.run(Engine.java:63)
17:13:43 GMT+01:00 	at java.lang.Thread.run(Unknown Source)
17:13:43 GMT+01:00 	at ......remote call to HOSTNAME (Native Method)
17:13:43 GMT+01:00 	at hudson.remoting.Channel.attachCallSiteStackTrace(Channel.java:1356)
17:13:43 GMT+01:00 	at hudson.remoting.UserResponse.retrieve(UserRequest.java:221)
17:13:43 GMT+01:00 	at hudson.remoting.Channel$3.adapt(Channel.java:782)
17:13:43 GMT+01:00 	... 22 more

Additional: 22-May-2015:
This seems to happen in our environment when one of the external processes, launched as part of our test suite, does not terminate when requested and is still writing to its log file whilst the archiver is trying to archive it.
This may be corroborated by the finding here: https://bugzilla.mozilla.org/show_bug.cgi?id=1037031
Judicious killing of processes during test tear-down has made the problem go away.

Have you tried disable flexible-publish for artifact manager?

As I look at the TarArchiver, it seems to require the size being written ahead and then exact number of bites to be written.

Use cases:
#1) file is still being appended
#2) Someone truncates the file
#3) the file gets deleted before it opens the input stream.

The safest thing is to copy the file to make sure none of that happens but it will slow things down and might not fit to disk at all. But since this is about #1 which tends to be lot more common than #2 or #3, making sure not to write more than initial length seems to be sufficient to fix this.

Nor replies after olivergondza, closing.