Hi Scott,
The typical answers that I have received from customer support is to uninstall and reinstall the product. There have been other suggestions as well, but the bug related to burning a DVD with menus doesn't seem to have a fix.
Many users have reported this same problem, but the issue remains.
I have sent my concerns to Cyberlink Headquarters in Taiwan to inform them of all the problems users are having with this bug.
There is a work around...an easy way and a "hard" way.
The Easy way:
You can still burn your DVD project by selecting not to burn menus with it. If your DVD is separated into chapters, you won't be able to use this feature in the DVD menus since they are broken. What you can do, however, and this isn't a perfect solution, is to just add a freeze frame at the beginning of each chapter segment in your time line to "announce" each new chapter.
Your customer will be able to fast forward to each new segment that way and see where each chapter begins. Not a great solution, but at the moment, its better than nothing.
The "Hard Way"
This will take a little PC expertise. When you go to burn page after hitting the "burn" icon, do not check the burn CD box. Instead, check the "save to folder" or what ever that option says. Then, note where the save will be located in the box right of the checkbox. Or if you wish, you can select a location for the save where you want.
Next, go ahead and burn your project. Your entire project will be saved as a video and audio file at the location you or the program selected.
Next, you've got to burn the video file you just made to a DVD. At this point, everything you did for the chapters and dvd menus will be in this video file. (You'll have to make sure that your DVD menus are just the way you want them by doing a preview before you burn it.)
The next step is to get a burning program called DVD Shrink. It is free and can be located on the Internet. Download this program. Run the program and select "Open Files" at the top of the menu. From here, navigate to the saved folder where your video and audio folders were made previously.
Select the whole disc in the menu of DVD Shrink, put a blank disk in your burner, and hit "backup" at the top of the menu screen. This will bring you to another menu where you select the proper options as which DVD drive you want to burn, and a location to store the temporary files. You may have to make a new location for this. You *don't* want to save these temporary files in the same VS (video folder) that has your saved PowerDirector burn folders.
Make a copy and you should have all of your menus and DVD in tact. I know this is a crazy way to do things, but since there is no admittance that there is a bug with PD7 by Cyberlink, this is the only solution/ workaround. And yes, it's ridiculous.
Sorry to hear you're having the same problems as others on here. Hope these "solutions" help.