Nearly three years later but just wanted to say thanks to Nate for answering this...
I had the exact same problem (worked unjar'd, threw the classNotFound when the application was jar'd). Interesting though, Sun says you don't need a codebase if you're using 1.5 (which I am). How come I needed the codebase afterall?
Sun's example and explanation Note: If the server needs to support clients running on pre-5.0 VMs, then a stub class for the remote object implementation class needs to be pregenerated using the rmic compiler, and that stub class needs to be made available for clients to download. See the codebase tutorial for more details.