Why not use the Bentley supplied pdf.pltcfg?
What version of Microstation are you using?
Microstation CONNECT - 10.17.2.61
ORD - 2021 R1 10.10.1.3
ORD 2022 R1.1 - 10.11.3.2
ORD 2022 R3 - 10.12.2.4
Microstation v8i SS 10 - 08.11.09.919
Power InRoads v8i - 08.11.09.615
ProjectWise - 10.0.3.453
Besides using the Bentley delivered PDF.PLTCFG to create your .pdf file. See if the issue is isolated to the "Cute PDF" driver. Using the same .pltcfg print to paper and see if you have the same issue. If not, make sure you have the most current version of the "Cute PDF" driver.
For some reason your replies are not following the thread. Would it be possible to try at a very minimum MicroStation V8i SS4 (08.11.09.529). If you can send me a private message I can try to see how it looks.