I have two 2016 Radrovers with 4000 miles on each ebike.  I rotate between both work commuting and weekend trail riding. Both are still operational with the same mix of controllers, brake pads, squeaks/rattles, weaker batteries, and tires.  I have similar upgrades with racks, rack bags, aux lights, upgraded pedals/grips, suspension seatpost, etc.

I don't wet weather ride my Rovers when possible.  I picked the Rovers because the company was from the Seattle area and built to be wet weather resistance.  I think salt water is the achilles heel for any electronic device.  I don't think the Rad Power Bikes since 2015 have improved to handle more than falling rain or freshwater tire splash from a puddles on the electronics?

I would think you would eventually have the exact same issue with a brand new Rover compared to your old?  You might have to factor in the cost of current/future repairs of your old Rover over time compared to Buying new Rover for $2000+future repairs.  I imagine there are types of grease, gels, tapes, wraps, oils, maintenance routines, and cleaning routines I could use to help reduce the effects of salt water damage with the old and new Rover.

I zip tied it pretty good and the wife didn't notice the extra cable length.  Hopefully, this will fix the issue and not be a normal replacement item.  I have two 2016 Radrovers with 3 controller replacements the first year of ownership between them.  The Rovers have been rock solid since the 1 year warranty expired in 2017 (8000 miles between both ebikes).

I have the 750w USA version.  I didn't measure the difference between the old and new controller wires.  I tried to stuff what I could inside the bottom of the frame and folded and zip tied the rest on the outside.  It seemed like the controller looked like the one used for the older Radcity 5 with the controller located near the top of the large downtube near the handlebars?

I purchased a Radcity 5+ for my wife in June of 2023.  We had the exact issue with zero PAS/Throttle power to the rear hub with 16 miles on the ebike.  Everything else worked like the lights, brake light, LCD, and no errors on LCD screen.  Rad sent a new controller after trouble-shooting and sending videos of the issue.  The replacement controller cables were longer than the original and that made it a little harder to install.  Everything is working for now; but, only put 70 miles on the Radcity since the fix.

I purchased a Radcity 5+ step-thru at the end of June 2023 and the controller went out with 16 miles on the ebike.  Some back and forth trouble-shooting with videos sent for Rad's confirmation of the issue.  I had zero power to the rear hub motor with PAS or throttle with no error codes on the LCD.  Everything else worked properly like the headlight, brake light and display. 

The new controller arrived around a week later.  The replacement controller cables were longer than the original and I had to stuff the extra in the frame or zip tie up the extra length on the outside.  The step-thru controller was located at the bottom of the inside of the frame near the pedal cranks.  It was easier to take the old controller out compared to replacing.  I couldn't get the new controller lined up to secure with the bottom exterior screws because to the extra cable length and tight space. I just gave up and didn't install the screws and taped up the screw holes to keep out water/debris.  The Radcity powered up and PAS/throttle worked perfectly since (only about 70 miles since fix). 

How many mile are you planning to ride per week, month, or year?  How many years are you planning to keep  your ebike?

I have two 2016 Rad Rovers with around 4000 miles on each with the older 11.4 Ah batteries.  I do have a spare 11.4 Ah battery I rotate in/out to spread the usage between the two ebikes (and extra spare for long rides).  I've lost a little range from 28-32 miles range new at PAS 2/3 down to 22-26 miles range after +8 years.  I also work commute if the weather is good.

I have no clue on how many cycles I have between the 3 battery packs?  I usually charge 100% if I know I need the range for a long ride of +20 miles.  Most times I just keep the same charge if my rides are shorter and charge up once I get below 20%.  I store the battery at 1/4 to 3/4 range for storage until needed.

I've lost some range; but, I still can do most of what I need to do with my riding routine.  I don't think the 800 cycle limit will be an issue unless you are planning to keep your ebike close to a decade or put +5000 miles per year for 4-6 years straight.

You might need to call Rad to find out the exact warranty period and any adjustments?  I purchased a RadCity Step-Thru at the end of June of 2023 with a extended warranty.  The ebike didn't arrive until July.  From what I can tell, the 1 year warranty and Rad extended warranty started when the order was made in June; not, the FedEx July arrival time.

My wife is 4'11" and we both have 2016 Rad Rovers.  This is way before the Rad Rover offered a fat tire or regular step-thru model.  She was able to ride the Rad Rover; but, she didn't like how big it felt (like riding a small motorcycle).  She also doesn't like to ride off road, no rough/sandy terrain, and she sticks to paved roads and occasional very flat double wide hard packed trails.  I upgraded her to a 2018 Radcity Step-thru with smaller 2.3 inch tires and she loved that way more.  Both the Rover and Radcity come in around the same weight.  The Radcity Step-thru was easier for her to push around the garage, easier to help lift on bike rack, smaller storage footprint, and felt easier to her to maneuver when riding.  I just upgraded her again to a 2023 Radcity Step-Thru (I still ride the two 2016 Radrovers and have the 2018 Radcity).

Another minor issue with the Radrover if you have short legs was it sat too tall to add a suspension seatpost like the Suntour SP12 NCX or Kinekt Bodyfloat seatpost and larger Cloud-9 seat .  The Radcity sits a little lower if you plan to add a different seat with or without a suspension seatpost.

I removed the Rad seat and re-used the seatpost for the Cloud-9 at first.  I later upgraded my seatpost to SunTour SR SP12 400mm suspension seatpost and later to the Kinekt XR 420mm Suspension seatpost.  The only issue I had was with my wife being 4'11" and the SunTour SP12 350mm+Cloud-9 was too tall for her on her Radcity Step-thru. I upgraded her to the 350mm Kinekt Suspension seatpost with the thicker Cloud-9 seat because it had a shorter overall suspension seatpost mechanism.  We are round 6-7 years with the Cloud-9+Kinekt seatpost for our Rad ebikes.

My favorite large seat is the Sunlite Cloud-9 Cruiser seat 11X10X8 size, Amazon, $37.  I use the Cloud-9 on my two 2016 Radrovers and two Radcity Step-Thru (2018 & 2023 models).  Works equally well for me (6'3" 300lbs) and my wife (4'11" 130lbs).

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I hear you on the mid-motor belt drive ebike.  I would love to update to one; but, prices need to drop by around 30% before I jump to one.  I haven't checked into how long the belt will last or how often you need to service the transmission part?  I imagine it isn't every few weeks to few months like my current chain drive ebikes.

I have two 2016 Radrovers with around 4000 miles on each with original chains.  I live in the desert southwest and "try" not to ride in the rain because the fat tires can soak me down like a garden hose.  I use Finish Line Dry Teflon chain lube because of the dry and dusty conditions.  I just got into the habit of cleaning my chain every few weeks to few months depending on how much I ride (Pedro's Oranj Peelz degreaser+park tool chain cleaner).  I can go months in-between cleanings if I'm 100% pavement work commuting; but, have to clean after a few weeks if I add in any trail rides.  So far, I haven't notice any rust spots or issues with my original chain after +8 years.

Maybe the rust spots are from where the lube has rubbed off and exposed to the elements?  I'm not that precise when oiling my chain and dump a steady stream of dry lube as I run the chain backwards. This also adds a layer of teflon on the gear teeth and I also do a steady stream of lube on all gears 1-7. I use a paper towel next to dry up any excess (clean up any drips on rear rim or derailleur parts).  Maybe not the correct way to lube a chain; but, my rover's chain and derailleur wheels/gears seems to run without issues so far.

I would also double-check the tow rating and tongue weigh limits of your vehicle. Usually; but, not always the tongue limit is about 10% of max towing (1500lbs towing/150lbs tongue limit).  Sometimes the same racks come in 1 1/4 or 2" sizes and others only have one size with and adapter for the different size hitches.  Those adapters can lower the max weight and max tongue limits sometimes depending how long they are.  You might have to add anti-sway/anti rattle device and extra hitch lock for some adapters.

I just worry too much and tend to be be overly cautious. I figured if a rack max weight is 60lbs per tray and I have two ebikes would equal 120lbs resting weight.  Then I worry about driving +70 mph on the hwy or hitting bumps/dips and how much stress and fatigue on main arm on the maxed out bike rack. A 120lbs of ebikes might feel like 180lbs sporadically on the rack on a bumpy washboard trail.  I'm just not certain if 2X60lbs is the absolute max or did Saris build-in a buffer of +/- 30lbs for extreme conditions.  One of my reason for upgrading to Quikrack with 240lbs limit for 140-160lbs of ebikes.

I have a lot of goathead stickers in NM and was getting flats several times a month with my 2016 Radrover with Kenda tires.  I added Mr. Tuffy liners and two  2oz bottles of Stans tire sealant to each tire.  My flat went down to 1-2 times a year.  Those yearly flats were from larger debris that created a hole too large for Stans to work (have a spare tube for those occasions). I usually have to add a 2 oz bottle a few times a year because of it working so much patching holes as I work commute or dirt trail ride +1000 miles per year.

I decided to upgrade my +7 year old solid steel +60lbs Saris Superclamp 4 bike rack.  The Saris rack was bulky, heavy, hard to store, required tools, and lifting the ebikes into the trays was getting increasing more difficult as I got older. I was pushing the weight limits with two 2016 Radrovers and/or 2018 Radcity (always only 1-2 ebikes at most or 2 ebikes+1 or 2 pedal bikes).  Noticed ebikes are starting to get heavier with longer wheelbase since my original purchase. 

Planning to upgrade my old Radrovers soon and might jump ship to Himiway Cobra or Cobra Pro at 88lbs and 51" wheelbase.  Narrowed down my choices for dual rack system for 2" hitch to a dirt bike rack like from Black Widow or Quik Rack Mach2 from QuikRstuff.  Decided on the QuikRack with 120lbs weight limit for each of the two racks, no tools needed to install, no bike prep like removing battery/seat/rack bag, no additional straps, only a few minutes to take on/off, folds for storage at home or trunk/hatch, and an option for a ramp that attaches to the rack.  Expensive and long wait times of 6-8 weeks.  Not expecting to get the new rack until the end of Sept or Oct; but, still have the Saris until then.