When you view and print the report in Crystal itself, how does the line look?
Also, when displaying a report on a website, depending on the viewer settings, the output may be converted to html - at that point what you see on the screen may different from what Crystal will output. You can try setting the option in the viewer to show ActiveX output instead of html output, which will give you a much more wysiwyg view of your report and what it will look like when printed through the ActiveX control. If you're using the PDF print control, you need to be aware that, while PDF export from Crystal is better than the other export formats, lines don't always export well no matter what format you're exporting to. There's nothing that can be done to fix that.
-Dell