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The short answer is to never print from the .CHM. Instead, provide a .PDF that your users may print, should they desire killing trees.
Seriously, there are numerous issues when trying to print from .CHM files and the result is seldom satisfactory. This is because as you try to print, things are copied to a temporary folder and the links to your associated style sheets get munged in the process.
Yes, I do plan to provide a pdf file, but users will find a need to print a topic on occasion for specific reference, so i would like to try to find the answer to the problem. Seems odd that the font size should change on printing, when it appears ok in the help window.
I found for one topic where i was having this problem, that if i inserted temp topics in between the start to the end of the document, that after inserting a new temp topic, the portion above printed ok. I repeated this several times, removing the adding temp topics, and eventually was able to get one topic i was having trouble with to print ok start to end.. I have other problem topics (long in length) and am unsure if this will work, but will give it a try. I was hoping there was something i was overlooking in the topic itself that was casuiing the problem, but given that it prints ok in Win2000 output, guess not. If you have other suggestions, please let me know.