2000 Insight 5 speed repair & build thread

[Daox]

Thanks, that should do the trick!

Any specific suggestions on specific components to use, or just grab whatever?

Also, is there anything to the harness, or does it just extend the wires inside the battery case to the charger?

[Ecky]

You can dredge the details of the harness out of my build thread too, but in short, you want a fuse close to the battery on one or both of the terminals. Don't use diodes or you won't be able to discharge. Mostly, it's just a +/- 144v to the battery, and a +/- 12v to the cooling fan. I used speaker wire and molex connectors from a PC power supply.

[Daox]

I'm also still quite interested in some decent floor mats for winter if anyone has any Insight specific ones I'd love to hear about it. With the massive holes in my carpet it'll come in quite handy. I'm thinking though at this point I'll just go find a universal set and cut them up to fit.

[Daox]

Thanks for the awesomely organized build thread Ecky! It is super helpful.

Last night I ordered the two 90V LED drivers from amazon. The total was about $25. They should be here in a week or two. I think I have the rest of the components for the charger here minus a nice 200V panel voltmeter. For now I think I'll just use my multimeter. I'm hoping this won't be something I use THAT much.

[Ecky]

Later in my build thread, I rebuilt my grid charger using a Meanwell 500ma power supply, rather than the 2x 90v LED chargers. The meanwell unit is a bit more expensive but has a wider voltage range so I can use it when it's really cold outside. On the other hand, 500ma is almost too much current, and should not be used when it's really hot outside. 350ma is a better/safer charging current.

[cowmeat]

Later in my build thread, I rebuilt my grid charger using a Meanwell 500ma power supply, rather than the 2x 90v LED chargers.

*after I killed it

[Ecky]

No worries.

[Daox]

The Insight is now officially on the road. I went out to go to work on Friday and I smelled gas when I walked up to the Metro. I had smelled it very faintly one or two other times in the past week. That morning the smell was very strong. Thus, the Insight is now on the road.

So, I need driving tips! My daily commute is roughly 1 mile 25-35 mph on each end of my commute. Between is 5 miles of 45 mph rolling hills. The trip to work is mostly downhill where the trip back is mostly uphill. I assume the Insight will really shine on this commute assuming I can keep it in lean burn on the way home. But, I need help learning how to drive this thing best. Thanks!

[Ecky]

To get my numbers, I generally try to keep my RPM below ~2200 when accelerating, and above ~1200 when cruising. E.g. I can cruise in 5th at 30mph, but I find I get slightly better economy in 4th until ~35. I avoid using assist unless it can prevent the need of downshifting out of my ideal rev range. There's some debate as to whether cruising in 4th in lean burn is better than 5th in stoich when you're in that area where you need slightly more power than 5th can deliver in lean, but my experience has been that it's (marginally) better to keep the revs lower. YMMV.

The only time I really use my kill switch is when my battery is >75% and when there's a hill whose slope is just right for maintaining speed in neutral, and I'd lose speed if engine braking, but I use my regen button a lot. If you can keep your battery above a certain level (~75-80%?) it seems like there's no background charging and mileage improves.

Other than that, just normal driving techniques; conserve momentum, keep the A/C off, look ahead.

[Daox]

I took it for a shorter spin around the neighborhood other day. The EGR plate cleaning definitely didn't fix the bucking issue, though I'm sure it didn't hurt. I'm still getting some pretty violent bucking. When wound up, I got a flashing engine light as well which likely means misfiring. I'm going to get new plugs ordered up today after I verify the spark plug index codes on the head. After that, if it persists I'll be looking at the ignition coils and other stuff.

Still, with all that and my trip in to work today, I managed 51.2 mpg. I think at least. I reset the trip A before setting out and that is what I'm at. Unfortunately I have to add another item to the list to fix too, and that is the trip button which doesn't work.