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Thank you both for keeping at this — the split page report is what let me find it, and I am sorry it took a version this long.
I can reproduce it now, and I know what it is.
Readium reserves a strip of vertical space above and below the page. I had assumed that reservation was there to clear an app's own toolbars, and since Leafmark draws its chrome as a transient overlay I cut it down to 20pt to reclaim the white bands in landscape. That reservation is not decoration: it is what makes a paginated column end exactly at the page boundary. With it cut, the column runs past the bottom of the page and the first line of the next page shows up under the current one. Because it depends on how the line height divides into the page height, it comes and goes with font size — which is exactly what you both described.
It has been in every build since 1.6, on every book including the bundled Frankenstein. So this was not something on your end.
The fix is to put Readium's default reservation back. I have verified on device that the overlap is gone. It is in the next submission to Apple, so it will take a couple of days to reach you.
The trade-off is that the landscape white bands come back for now. I would rather have correct pages than reclaimed margins, and I will solve the landscape spacing a different way rather than by taking that reservation again.
If you see anything still splitting after that update lands, please say so here.
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