It's reproducible. Using recovery tool on cyan, creating Acer Chromebook 11 image. 
Feedback report:
http://feedback/#/Report/12534213415

I got the same error when creating an image for the Asus Chromebook Flip C100 as well. Exact same error message.

651907 has additional information on this issue (duplicate).

Moises, any ideas on how this might be broken?

Facing this issue on ChromeOS, Windows and Mac.

If the files are not the right size, my initial suspicion is that the upload of the files never really completed.

We are using a new tool for uploading the recovery images, and this morning was the first attempt to update the entire fleet at once (it seems to have worked for a few systems previously ok). 

We think some bad metadata is causing the issues but are still looking into it. In the meantime, configurations files have been reverted back and users should be able to recover to old Chrome OS versions. New recovery images are on the way to be pushed but that could take up to a day to propagate.

Recovery tool failed either  
- "Select a model from a list" or 
- when entering CYAN-D25-D4B-E6A-A3j from cyan.    

Recovery tool failed all boards (tested cyan/minnie/link/big) 

Now recovery utility error (at verify stage) is gone, and image is written to external storage.

 Issue 651907  has been merged into this issue.

We went back to the old (slow) tool which just finished, I verified I can get a .93 image for Samus off of the recovery tool it is believed to be in a good state now.

We can mark this as fixed, or leave it open for investigation on the new recovery push tool, though that may be better tracked internally.

Team, this was an unusual, but understandable issue. The base problem is error handling messages in the Recovery app. We need error messages that can be understood by non-technical users.

A similar problem occurs when the recovery media is too small,or has other problems. Please see this recent CBC thread
https://productforums.google.com/forum/#!topic/chromebook-central/yjd1trty2Dw;context-place=forum/chromebook-central

Note the rather extreme steps that we provide to users to positively ensure that the recovery media is properly erased and formatted. It also appears that the recovery image may need a larger than 4GB device now for some boards.

I request that Recovery Utility check and report these issues:

1. Sufficient capacity media - is a nominal 4GB device OK, or should an 8GB device now be used? Recovery app says 4GB, the Help page does not specify. See attached screenshot from user for error encountered that appears to be a capacity issue.

2. Properly partitioned and formatted media - detect existence of improper partitioning (new SanDisk device is common example because of hidden partitions) and initiate the "Erase" action if needed.

3. Properly formatted media - if needed. Does the media have to be formatted before starting Recovery app, or is it ready immediately after an Erase? Again, the status/error messages do not indicate what Erase actually does, and Recovery does not mention formatting.

Thanks,
Jim Dantin, CBC TC
#CBC-RS/TC-watchlist

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The recovery images should not need an 8GB stick just yet, the largest uncompressed we have currently is ~2.2GB (including the Play Store), so a 4GB drive should work, there may come a day in the future we don't fit but that is probably a ways off.

The SanDisk hidden partition is an interesting case, when I write these recovery images out locally I use dd from Linux machine, which is fairly heavy handed and should overwrite any sort of hidden partition. I imagine the recovery tool here is doing the same thing, I am not sure how the SanDisk is breaking this way unless it is doing something very non standard.

The method used by the recovery tool should be effectively formatting it, no prior preparation should be necessary. The recovery image file contains the formatting already, and we essentially write it over the beginning of the drive. 

Please try using a new SanDisk USB drive with a Chromebook rather than Linux box. We consistently see issues unless they are re-partitioned before use.

Is https://www.amazon.com/gp/product/B00E9W1ULS/ref=s9_top_hd_bw_bDDqV_g147_i1?pf_rd_m=ATVPDKIKX0DER&pf_rd_s=merchandised-search-5&pf_rd_r=X6XEF205MD3GFHJEF1N9&pf_rd_t=101&pf_rd_p=191c3a37-8720-55bc-8d1f-1a18d621f2a7&pf_rd_i=3151491&th=1 believed to do this?

If so I can order a couple and give it a try. 

That model refers to downloading software.

This one says it is already included on the drive. I own this model and can confirm that there was a second partition when I received it.
https://www.amazon.com/dp/B005FYNSUA/ref=twister_B00JO6RO8C?_encoding=UTF8&th=1
Protect Your Private Data
SanDisk's signature SanDisk SecureAccess software, which enables you to password-protect and encrypt your private files, is included with the drive. 

Thanks, ordered. I think this is a bit separate from the original issue so we may want to track this elsewhere.

Closing this bug as Bernie updated the recovery images with the old tool, the new tool bugs are now being tracked internally.

For the SanDisk issue a new bug is advised.

I tried to download a recovery image for Acer R11 today, and it is still failing.

I tried it several times, all of them with same results.
Download completed, verify completed but when unpacking, it stops and shows : “Unable to unzip file. Please try again”

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I just tried this locally and it seems to be ok, this maybe some separate issue.

On the system you are using to generate the recovery image is there any chance it is low on storage space (needs to fit a ~2gB image)? Not sure what else might cause it to be unable to unpack the image.