Printed PDF does not match what is on screen

Not sure this is the right place to post (have just posted on Adobe's equivalent of this - belt and braces), but I am having an issue with PDFs when printed vs. what they look like on screen.
In short, when they are printed, it is as if there are some margins someplace that result in the printed image being reduced in size. I do not know if this is an issue with Acrobat Reader 5 on OSX, an issue with how Reader is reading the PDF, or what, so ideas would be welcome.
The PDF's are being created in Illustrator 9.x running under Classic and there are no margins coming through from that application (they have been removed, just in case). I know that upgrading to OSX versions would be smart, but it is very expensive and the PDF, if it lives up to its name. ought to behave properly!
I am looking at this MO, because my OS9 compatible printer died recently and there are no drivers for OS9 for the new one, so i cannot (reliably) print directly from the OS9 apps to the new printer, hence going via PDF. The problem was present with the old printer as well, but as I could go direct from the apps to that, it didn't matter.
Happy to clarify further if needed.

Try using the "classic" PrintToPDF @ http://www.jwwalker.com/pages/pdf.html
This way you will be creating a PDF file using classic instead of OS X's Print To PDF.
 Cheers, Tom

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