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The problem occurs on my server (with Redmine 2.5.2 / ruby 2.0.0 and no plugin) but everything seems to work fine here...
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Can you try to reproduce: 1/ on redmine 2.5.2 with ruby 1.9.3, 2/ on current trunk ? Anyway the stack trace would be helpful (I have access to this through our common instance but not other contributors ;)). Maybe we can force encoding somewhere.

Note that I'd like to see it reproduced on current trunk because r13358 has extracted the vendored rfpdf plugin and we will use the gem starting with 2.6.0, so I'd like to see if issue is the same with that. But if we can fix that for 2.5.3, let's go then ;-)
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PDF export works fine with ruby 1.9.3 and redmine 2.5.2.
The error occurs with ruby 2.0.0 and ruby 2.1.2.

Here is the stack trace:

ArgumentError (invalid byte sequence in UTF-8):
lib/plugins/rfpdf/lib/tcpdf.rb:3037:in `gsub'
lib/plugins/rfpdf/lib/tcpdf.rb:3037:in `escape'
lib/plugins/rfpdf/lib/tcpdf.rb:3028:in `escapetext'
lib/plugins/rfpdf/lib/tcpdf.rb:1748:in `Cell'
lib/plugins/rfpdf/lib/tcpdf.rb:2021:in `Write'
lib/plugins/rfpdf/lib/tcpdf.rb:3530:in `block in writeHTML'
lib/plugins/rfpdf/lib/tcpdf.rb:3501:in `each'
lib/plugins/rfpdf/lib/tcpdf.rb:3501:in `writeHTML'
lib/plugins/rfpdf/lib/tcpdf.rb:3612:in `writeHTMLCell'
lib/redmine/export/pdf.rb:141:in `RDMwriteHTMLCell'
lib/redmine/export/pdf.rb:601:in `issue_to_pdf'
app/controllers/issues_controller.rb:133:in `block (2 levels) in show'
app/controllers/issues_controller.rb:125:in `show'

I will try with the last version from trunk.
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Vincent Robert wrote:
> PDF export works fine with ruby 1.9.3 and redmine 2.5.2.
> The error occurs with ruby 2.0.0 and ruby 2.1.2.
>
> Here is the stack trace:
>
> ArgumentError (invalid byte sequence in UTF-8):
> lib/plugins/rfpdf/lib/tcpdf.rb:3037:in `gsub'
> lib/plugins/rfpdf/lib/tcpdf.rb:3037:in `escape'
> lib/plugins/rfpdf/lib/tcpdf.rb:3028:in `escapetext'
> lib/plugins/rfpdf/lib/tcpdf.rb:1748:in `Cell'
> lib/plugins/rfpdf/lib/tcpdf.rb:2021:in `Write'
> lib/plugins/rfpdf/lib/tcpdf.rb:3530:in `block in writeHTML'
> lib/plugins/rfpdf/lib/tcpdf.rb:3501:in `each'
> lib/plugins/rfpdf/lib/tcpdf.rb:3501:in `writeHTML'
> lib/plugins/rfpdf/lib/tcpdf.rb:3612:in `writeHTMLCell'
> lib/redmine/export/pdf.rb:141:in `RDMwriteHTMLCell'
> lib/redmine/export/pdf.rb:601:in `issue_to_pdf'
> app/controllers/issues_controller.rb:133:in `block (2 levels) in show'
> app/controllers/issues_controller.rb:125:in `show'
>
> I will try with the last version from trunk.

I think your ruby 2.0.0 and 2.1.2 are broken.
Because Redmine 2.5 uses 'ASCII-8BIT'.
source:tags/2.5.2/lib/redmine/export/pdf.rb#L787
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I cannot reproduce.
<pre>
$ ruby --version
ruby 2.1.2p95 (2014-05-08 revision 45877) [x86_64-linux]
</pre>

!pdf-issue-notes.png!
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Did you try with Redmine 2.5.2?

It appears the error is gone with trunk version of Redmine. It only occurs with 2.5.2 and ruby > 2.0.0 (I reproduced the bug on my Mac, but also on a linux server and even on Heroku ;)
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Try this patch.
<pre><code class="diff">
diff --git a/lib/plugins/rfpdf/lib/tcpdf.rb b/lib/plugins/rfpdf/lib/tcpdf.rb
--- a/lib/plugins/rfpdf/lib/tcpdf.rb
+++ b/lib/plugins/rfpdf/lib/tcpdf.rb
@@ -1,3 +1,5 @@
+# encoding: ascii-8bit
+
#============================================================+
# File name : tcpdf.rb
# Begin : 2002-08-03

</code></pre>
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Vincent Robert wrote:
> Did you try with Redmine 2.5.2?

Sorry, I can reproduce on Redmine 2.5.

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Great! It works perfectly with this patch.
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Fixed in 2.5-stable r13370 and 2.4-stable r13371, thanks.
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