I think there might be something to that small font theory at the young ages.
There is. When our older one was 3 and started reading chapter books he also started complaining about his eyes hurting. It happened usually during reading but sometimes even without it. I took him to an ophthalmologist who said his eyes were ok and that he complained to get my attention.

Yeah, right
It went away in a few months and he has no problems now but looking back I think it was all thanks to the smaller print in the chapter books.