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