Issue #20897 has been updated by Bob Maerten.

The situation in which the problem occured is after upgrading my Debian Wheezy 
server. Updates were available from puppetlabs repository and puppetmaster was 
upgraded to 3.2.1. After that, I restarted my puppetmaster-passenger service 
(by touching the tmp/restart.txt file).

Unfortunatly, the default config.ru file does not enable debug so I did'nt 
notice anything weird until I manually triggered a puppet agent on one of my 
nodes.
The error message is:
        root@node1:~# puppet agent -t
        Info: Retrieving plugin
        Info: Loading facts in /var/lib/puppet/lib/facter/...
        [..snip...]
        Error: Could not retrieve catalog from remote server: Error 400 on 
SERVER: invalid byte sequence in US-ASCII at 
/etc/puppet/environments/production/modules/concat/manifests/fragment.pp:41 on 
node node
        Warning: Not using cache on failed catalog
        Error: Could not retrieve catalog; skipping run

(concat is a puppet module installed through a dependency of mysql or 
postgresql I think)

I have similar error, but with no file involed with another node (fewer rules 
on this one):
        root@node2:~# puppet agent -t
        Info: Retrieving plugin
        Info: Loading facts in /var/lib/puppet/lib/facter/...
        [...snip...]
        Error: Could not retrieve catalog from remote server: Error 400 on 
SERVER: invalid byte sequence in US-ASCII
        Warning: Not using cache on failed catalog
        Error: Could not retrieve catalog; skipping run


I activated DEBUG in the config.ru file and syslog I not much helpful:
        May 29 11:00:36 puppet puppet-master[20728]: Caching catalog for node1
        May 29 11:00:36 puppet puppet-master[20728]: Searched for resources in 
0.00 seconds
        May 29 11:00:36 puppet puppet-master[20728]: invalid byte sequence in 
US-ASCII
        May 29 11:00:36 puppet puppet-master[20728]: Handling request: PUT 
/production/report/node1
        May 29 11:00:36 puppet puppet-master[20728]: Received report to process 
from node1
        May 29 11:00:36 puppet puppet-master[20728]: Processing report from 
node1 with processor Puppet::Reports::Store

So here is all I can find for you to get this through :\ and the solution 
exposed in bug #19655 seemed quite acceptable to me at the moment, in order to 
make my puppetmaster work again.

----------------------------------------
Bug #20897: puppet agents complain about master not-being UTF-8
https://projects.puppetlabs.com/issues/20897#change-91737

* Author: Bob Maerten
* Status: Needs More Information
* Priority: Normal
* Assignee: Bob Maerten
* Category: 
* Target version: 
* Affected Puppet version: 
* Keywords: 
* Branch: https://github.com/puppetlabs/puppet/pull/1666
----------------------------------------
I had this error after updating to 3.2.1 when I tried to fetch catalog from 
agents

Error: Could not retrieve catalog from remote server: Error 400 on SERVER: 
invalid byte sequence in US-ASCII

My config is Debian based, with packages installed from puppetlab repo. 
PuppetMaster is served through puppetmaster-passenger.
I managed to get it working back by adding these lines to my config.ru:

Encoding.default_external = Encoding::UTF_8
Encoding.default_internal = Encoding::UTF_8

and my agents went back to normal behavior.


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