Karl, I didn't think the "build light, fix broken stuff" method implied that it would be tested on consumers. I took it to mean "build light and test, then make it so things don't break, then sell it." It would be obtuse (I'm being kind) to assume it means to make a piece of crap product then give it to the market...
With a minimum payload of 100 lb and a maximum of 260, you are definitely near the max safe working load of the machine. However, Segway states that the platform is built to take several tons of stress. Perhaps it is a bit overbuilt?
I'm not really sure about your theories of the center of mass being higher causing the segway to require more torque. The segway is an inverted pendulum, and the lower the mass is (that is, the closer the mass is to the platform) the more it has to work to move. If I wore 80lb boots the segway would be working harder than if I work an 80lb helmet. I'm a bit fuzzy on the math, so I'm willing to be wrong here.
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