I have the 2008 BV250 and love it. I get better than 75 MPG and it does fine on the highway (70 - 80mph). Haven't 2uped with it so I have no experience with it when weighed down. I think it depends on what you will be doing. If you plan on a lot of higher speed touring, the 500 may be the way to go. If you are just an about town rider, the 250 should be fine.
Sorry, I should have added that I live outside Denver, Colorado and the hills and mountains have not been much of a problem with the 250. I do have trouble maintaining speeds above 80kph if there is a significant grade. I am an average sized guy so my size isn't a real issue. Not that you will have a mountain problem unless you head to Germany, Italy, etc.
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