Export to PDF spacing problems w Optima

I’m helping a friend troubleshoot a really weird problem exporting to PDF from InDesign. In one text block, the tracking/kerning is completely crazy. We’ve made sure that the font is a current version (font version 2.020). Wildly different from the ID document (looks as expected) and PDF (the word “Yellowstone” looks like “Yellows tone”)
Somehow, I managed to fix the problem in one version of the file he gave me for testing. Some combination of: setting a style rule, setting the kerning to Optical, removing local style overrides, choosing a different printer before exporting the PDF, or maybe something I forgot I had done messing around trying to figure it out. It’s driving us crazy, it’s for a multi-hundred page catalog. Also, using the Mac OS X PDF workflow or printing to PS and Distilling don’t have the problem, but either workaround is unappealing due to the workflow for output (includes “China” as part of the process).
Other things that will fix it include copying all the blocks on the bogus page and pasting them into a new document. I have even run “diff” on the idml exports (side note, you can open them with an archive expanding tool, such as The Unarchiver, they turn into folders) and don’t really see huge differences. I have exported the broken docs as idml and imported them, but that alone is not enough.

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