Hi,
I've encountered the same problem, where the font in a converted .pdf file has an extremely large font. After running the job for about 7 seconds the "Running PDF output plugin" starts and runs for an additional 30 seconds. In comparison, converting to ePub takes about 6 seconds total and works as expected.
I have restored default settings for the pdf output option and I've gone to Output Options/PDF Output and checked the "Override paper size in output file" and selected "a1" as paper size and set the default font size to "12 px" and the monospace font size to "10 px".
Regardless of the settings I get the same result.
I am guessing there is a simple solution but I can't seem to figure it out myself. Thanks for any suggestions

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Take care,
Thor