Extremely large jpg exported files - help!

I was previously loving LR3 - used the trial for a month, decided to buy it - had really no problems. The big issue for me is now the jpg export file sizes that are being created. I run all my photos through the develop module to adjust the basics as well as draw in masks, and previously I had no trouble exporting the files as jpg, with the limit of size at 600kb and resized to 960x640 (original photos from 5Dmk2 RAW).
Then I bought the license. From then on it seems that now whenever I do the same exact export it doesn't work! I also used to use the output quality slider and set that at 100% and would get around the same file sizes, but now I'm getting files 2-3x the size of the previous exports. All of the photos have minimal metadata (10 keywords or so, that's it) and the same metadata was present in the exports in the trial version.
Playing around with more export parameters and reading around on this forum led me to try and minimize exif data - this didn't even work - files could not meet the requirements or they still ended up 2-3x the size they used to be.
The interesting part is that when I would delete all development history and set the file back to the original pre-edited RAW and export there would be no problems!
Could it be possible that LR is adding the development data into the metadata that it is attaching to the photo??
This has completely shut down my photo workflow and really is making me regret buying this otherwise wonderful tool.

What I can see in the image is that it contains about (uncompressed) 750KB of XMP data, the major part of it relating to some "PaintCorrection" as follows:
PaintCorrectionWhat             : Correction
PaintCorrectionAmount           : 1.000000
PaintCorrectionActive           : true
PaintCorrectionExposure         : 0.439246
PaintCorrectionSaturation       : 0.000000
PaintCorrectionContrast         : 0.000000
PaintCorrectionClarity          : 0.457077
PaintCorrectionSharpness        : 0.000000
PaintCorrectionBrightness       : 0.361949
PaintCorrectionHue              : 240.000000
PaintCorrectionSaturation       : 0.000000
PaintCorrectionMaskWhat         : Mask/Paint
PaintCorrectionMaskValue        : 0.689655
PaintCorrectionMaskRadius       : 0.005442
PaintCorrectionMaskFlow         : 0.000000
PaintCorrectionMaskCenterWeight : 0.843964
PaintCorrectionMaskDabs         : d 0.689505 0.619480
PaintCorrectionMaskWhat         : Mask/Paint
PaintCorrectionMaskValue        : 0.689655
PaintCorrectionMaskRadius       : 0.005444
PaintCorrectionMaskFlow         : 0.000000
PaintCorrectionMaskCenterWeight : 0.843964
PaintCorrectionMaskDabs         : d 0.689871 0.605390
PaintCorrectionMaskDabs         : r 0.005443
PaintCorrectionMaskDabs         : f 0.0813
PaintCorrectionMaskDabs         : d 0.689749 0.607832
PaintCorrectionMaskDabs         : f 0.1519
PaintCorrectionMaskDabs         : d 0.689626 0.610275
PaintCorrectionMaskDabs         : f 0.1700
PaintCorrectionMaskDabs         : d 0.689590 0.612722
PaintCorrectionMaskDabs         : r 0.005442
PaintCorrectionMaskDabs         : f 0.1759
PaintCorrectionMaskDabs         : d 0.689635 0.615026
PaintCorrectionMaskDabs         : r 0.005443
PaintCorrectionMaskDabs         : f 0.1742
PaintCorrectionMaskDabs         : d 0.689530 0.612581
PaintCorrectionMaskDabs         : f 0.1726
PaintCorrectionMaskDabs         : d 0.689425 0.610137
PaintCorrectionMaskDabs         : r 0.005444
PaintCorrectionMaskDabs         : f 0.1709
PaintCorrectionMaskDabs         : d 0.689320 0.607692
PaintCorrectionMaskDabs         : f 0.1692
PaintCorrectionMaskDabs         : d 0.689214 0.605248
PaintCorrectionMaskDabs         : r 0.005445
PaintCorrectionMaskDabs         : f 0.1678
PaintCorrectionMaskDabs         : d 0.689104 0.602803
PaintCorrectionMaskDabs         : f 0.1460
PaintCorrectionMaskDabs         : d 0.688982 0.602615
PaintCorrectionMaskDabs         : r 0.005444
PaintCorrectionMaskDabs         : f 0.1525
PaintCorrectionMaskDabs         : d 0.689069 0.605061
PaintCorrectionMaskDabs         : f 0.1569
PaintCorrectionMaskDabs         : d 0.689090 0.607511
PaintCorrectionMaskDabs         : r 0.005443
PaintCorrectionMaskDabs         : f 0.1625
PaintCorrectionMaskDabs         : d 0.689100 0.609960
PaintCorrectionMaskDabs         : f 0.1652
PaintCorrectionMaskDabs         : d 0.689195 0.612399
PaintCorrectionMaskDabs         : f 0.1863
PaintCorrectionMaskDabs         : d 0.689113 0.610052
PaintCorrectionMaskDabs         : r 0.005444
PaintCorrectionMaskDabs         : f 0.1845
PaintCorrectionMaskDabs         : d 0.688940 0.607617
PaintCorrectionMaskDabs         : f 0.1839
PaintCorrectionMaskDabs         : d 0.688743 0.605185
PaintCorrectionMaskDabs         : r 0.005445
PaintCorrectionMaskDabs         : f 0.1916
PaintCorrectionMaskDabs         : d 0.688549 0.602753
PaintCorrectionMaskDabs         : f 0.1748
PaintCorrectionMaskDabs         : d 0.688555 0.604775
PaintCorrectionMaskDabs         : r 0.005444
PaintCorrectionMaskDabs         : f 0.1839
PaintCorrectionMaskDabs         : d 0.688622 0.607222
PaintCorrectionMaskDabs         : f 0.2225
This data results from heavy use of the local adjustment brush. Choosing "Minimize Embedded Metadata" upon export really should solve this problem for you. Please try again specifying this option.
But then, by doing so, you lose any other metadata (keywords etc.) also. To have complete control on what metadata gets written into the JPEG upon export, you could use Jeffrey’s “Metadata Wrangler” Lightroom Plugin.
I noticed one strange thing within the XMP data in your JPEG:
The data seems to be formatted differently than what I see with JPEGs I export ("HasExtendedXMP"), which I don't know where it comes from.
For further investigation, would it be possible for you to upload the Raw file and the XMP file belonging to it to somewhere (e.g. www.yousendit.com) and post a link to it here?
Beat Gossweiler
Switzerland

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