PDF/CD-ROM Question for Designers

I’m a web designer with Flash experience and while I have produced CD-ROM video brochures in the past (to see an example I designed, Click Here!) but I haven’t put a PDF document on a CD-ROM which explains why I’m reaching out to my colleagues here for help.

I’ll be creating the project most likely in Flash or Dreamweaver, depending on which seems easiest (unless there’s other software that can be suggested!)

I also have photoshop, and adobe reader at my disposal.

My client wants their 200 page PDF brochure placed on a CD-ROM that auto-launches the first page of the brochure within some type of PDF viewer. To the left of the viewer an index of chapters will appear, giving the viewer the option of clicking on the chapter of their choice and, when they click, the PDF viewer to the right will automatically jump to the page they selected. Because I haven’t done this before here are my questions:

Q1: I’ve been producing video CD-ROM’s that auto-launch onto the disc with pixel dimensions of 800 X 600 (see link above), do you recommend these dimensions for this PDF/CD-ROM project?

Q2: What PDF viewer tool would you suggest I use for this project?

Q3: Does anyone know of a good, free software tool (freeware) I can download and use which will help me create links from the chapter index on the left side of the brochure with the PDF viewer on the right?

Q4: Will the dimensions of a much larger PDF document blur and become illegible when decreased to display at much small dimensions?
I mentioned the 800 X 600 Footprint earlier because this doesn’t take up too much room on the customer’s screen when the brochure auto-launches. However, the dimensions of the client’s PDF are 838 X 1172. Is this too big? Will it cause blurriness when reduced in pixel dimensions to the viewer? Should I ask my client to give me a new PDF that’s no taller than 550 pixels?

Q5: the PDF document by itself is very large (it was made for print) at 60 Megs in size. Should I have my client send me a number of different PDF’s with each file representing a chapter in the index? Would the PDF load faster this way?

Thanks for any feedback…