How to export video that plays back smoothly?

I have an HD project in Premiere Pro CS4 that is about 9 minutes.  When I render out to Flash for the web, once it's all buffered it plays back real smooth.  So the client wants a copy of the "file" to be played on his computer running Windows and Windows Media Player which he will attach to a large 55" flatscreen via HDMI at a trade show.  I rendered out several different files ranging from .MOV to H.264 in various resolutions (1920x1080, 1280x720p, 720x480 wide, iPod, etc.) and tested them on my Dell Inspiron i3 laptop running Windows 7 Home 64 bit connected to my 46" tv via HDMI to simulate what the client would have.
The 1920 file was huge (2GB) as one would expect and plays back jerky
The 1280x720p .MP4 file was about 400mb which I was excited about, but plays back jerky
The other two (.MOV and .MP4) at 720x480 play back smoothly
So I'm guessing that it's either a disk / processor issue with playing back the larger files or combo of that and the graphics card or am I having an issue with the way the settings are set in the export options?
The box I'm producing the video on is a Mac i7 quad-core, 8GB RAM and a nice ATI card.  The full rez versions of the files play fine on it.  BluRay is out too.  Don't have a burner and they don't have a player.
So what file format and settings can I render out that will yield smooth(er) results at larger resolutions for my intended output?
Thanks,
Steve

And the answer is.... converting the footage to WMV.  Tada.  I exported a nice huge HD 1920x1080 H.264 file and then used iSkysoft Video Converter to convert it to WMV.  Now the only thing is that iSkysoft Coverter only allows 1280x720 as it's largest resolution for WMVs, but even so, the quality on a 46" LCD TV coming from a laptop via HDMI looks pretty sharp.  The video was running very smooth (and it was running off a USB key <g>) to boot.
The file size of the original HD H.264 file:  9.02GB
The file size of the converted WMV: 437.5MB
All in all I'm happy with this breakthrough.  I was "this" close to buying a BluRay burner, media and telling the client to use a BluRay player.
Now... I love what I got, but it could be better.  Does anyone know of a good video converter that will convert WMVs to true HD resolution (1920x1080) or is that 1280x720 a WMV limit?
Thanks all,
Steve

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