"A mans got to know his limitations" …
Found a great “old school” bike shop in a University town nearby (tons of positive customer reviews). I had ordered the Tannus Armor Inserts from them and decided to let them install them and work on the IGH. The cable started fraying last week and despite my adjustments it seems to have intermittent problems with all gears except high (5th) gear. I could get it shifting all gears reliably on the stand but once I start riding the mis/phantom shifts and clunking sounds from the lower gears would return.
They spent a few hours on the bike installing the Tannus and replacing my fraying shift cable and cable cover which too short and too long respectively causing binding and that's the reason for the "extra stiff" trigger shifter. All 3 mechanics test rode the bike and reported shifting was good in all gears, praised the smooth application of PAS, the motors power (it was in ECO mode) and how great the MD 1000 handled for such a big bike. It was interesting how much attention the bike got during the day by customers and the stores other employees (it's also a ski/snowboard shop). One guy there having some work done on his 20" fat tire folder ebike was really taken with the look of the MD1000. He was hard selling his wife on his getting one as I was loading up outside the store.
It was late so I only got in a quick ride around the neighborhood after getting home last night but will take a long ride today to confirm all systems are a go. I had planned on installing new Maxxis tires with the inserts but the orig tires are in near new condition so that seemed unnecessary. I expect I will get double the life out of the front vs rear (ex my fat tire folding bike is on its 3rd rear tire in 2500 miles while the original front is still usable. I think you can expect most ebikes to consume tires similarly but the Maxxis tires are something special in terms of handling and treadwear. Note, the Maxxis Minion 4.8" comes in FBR (rear) and FBF (front) versions.
So, it appears I’m all sorted out and now have ebike super powers with a solid drive train and the Tannus Armor Inserts. Just in time for Spring and looking forward to many fun riding miles this year.