Just a couple thoughts: my factory brake system, with the addition of a good set of pads and stainless lines, stops my ninja race bike with my 190 lb mass, from 100 mph with no problem. So look at it this way, every time I ride my bike I am threshold braking and my brakes hold up fine, as do the other riders on the track, some weighing more than me by 30lbs and some weighing less than me by 40lbs. So I don't think you will run into problems with the brakes from the added stress of the 500 motor on the street. Next, if you have a donor bike and the skill to fab this project, I don't see it running up the tab for the swap. Were do you need to spend $$$ with everything sitting right in front of you. Next, ask Racerx how his 60 hp bike is holding up to the constant hammering he puts it through. As far as I know he hasn't experienced any chassis related failures due to the added stress of more than double the HP.
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