I don't think the issue is a character limit, I think it's that you're using formatted text. You can't paste in stuff from an external source (e.g. Word), or it will break. Try transferring any text through Notepad/TextEdit first, or using Shift-Ctrl-V to paste in the Master Ballot box. You may also not be completely clearing out the content of the box, there can be hidden character/formatting codes there even if there's no text, so make sure to use Ctrl+A to select everything and delete before re-saving.
You don't need to re-section to get printing to work, you just need to make sure you don't have anything in the relevant boxes that will break the printout creator.
If the above doesn't get it sorted out, let us know.