Sean,
I know, I know: everybody's an editor, but how about this?
To create a PDF from FrameMaker make sure that you have installed the Acrobat Distiller printer instance. This is NOT done by using the Add Printer option found in Start > Settings > Printers. Instead:
1. Download the latest Adobe Universal Printer Driver Installer from Adobe.
2. Make sure you have the latest PPD file available. You will be asked to find it during printer installation.
3. Double-click the .exe file to install the driver you downloaded.
4. When you are asked for the PPD file, browse to find it on your system.
Now you will have a printer instance called Acrobat Distiller. Use this printer when you create PDF files or when you create PostScript files from FrameMaker.
Do not use Save As PDF! This seems handy, but doesn't let you control Distiller job options. Instead:
1. From your Frame file or Frame book file, Print.
2. Make sure to select Print to File.
3. Make sure that Acrobat Distiller is the printer selected. It is good practice to make sure Acrobat Distiller is the default printer for your system before you go from Frame to Acrobat.
4. Distill the resulting postscript file.
Using watched folders can make your Frame-to-Acrobat tasks nearly automatic. See the Acrobat Guide for more information.
***
Sean, I think that your post may give the beginner a little too much information they won't understand until they've been at this for awhile. The "If you are outputting to a service bureau..." part for example. I think the FAQ should answer the questions for beginners. As they gain more experience and confidence, they will start to do things your way--the daring Save As, for example!
Your troubleshooting ideas are great. Can you add, under the b&w or grayscale PDF problem that it might be caused by selecting Spot as Black in the Frame print dialog?
Hope I'm not too much a pain about this... Also hope I didn't mess up the details in my suggestions...
Jeanie