You want this page. It should answer your questions.
Edit: basically this (though there are other important bits):
FAQ wrote:
Does this mean I can write my own adventures for the Pathfinder RPG, set them in Golarion, put characters like Seoni and Valeros in them, put a Pathfinder logo on the cover, and distribute them via my website?
Yes, so long as you don't charge anything for them, and you follow all the other rules.
I'd ask before the first dice is rolled who will be listening at the door. If only the rogue says he is, then only the rogue gets to roll, regardless of the outcome.
I was going to say turn him into a grain of sand in the desert, that way he'll last forever, but you asked for non-character breaking. Have any damage he takes given to his nearest allies, so he never takes damage, but others take it for him.