The Honda Insight Hybrid is more than a technological showcase as it was produced and sold in Japan, the U.S. and Europe. The Honda Insight introduced in 2000, is a petrol-electric hybrid two-seater coupe that blends a mass of new technologies to achieve a very low fuel consumption for a mass-produced car.

Honda’s Integrated Motor Assist (IMA) hybrid system, featuring a high efficiency petrol engine, electric motor, and lightweight 5-speed manual transmission (front wheel drive), are used in combination with a lightweight and highly aerodynamic aluminium body to offer an outstanding on-road performance: ultra-low fuel consumption of 3,4 l/100 km EUDCC, emissions at 80g/km CO2, plus highly respectable performance figures of 0 to 100 km/h in 12 seconds and a top speed of 180 km/h.


The heart of the Honda Insight is a light 1.0 litre, 3 cylinder petrol engine which uses lean burn technology, low friction characteristics and lightweight materials in combination with a lean-burn compatible NOx catalyst. The electric component consists of an ultra-thin (60 mm) 10 kW DC-brushless motor directly connected to the crankshaft, 144 V nickel metal-hydride (Ni-MH) batteries weighting just 20 kg and an electronic Power Control Unit (PCU). The electric motor draws power from the batteries during acceleration (so-called Motor Assist) to boost engine performance to the level of a 1.5 litre petrol engine as well as acting as a generator during deceleration to recharge the batteries. This means that, unlike conventional petrol/electric hybrid systems, the Honda Insight is never powered by the electric power alone.

Most importantly, the Insight works just like any other car, and it works very well. It runs on regular unleaded gasoline, to the tune of 50-plus miles per gallon in normal operation, with 70 mpg theoretically possible. A 10-gallon fillup will get it at least 500 miles. Unlike other, more complex hybrid vehicles, the Insight never operates as a pure electric car. The “Integrated Motor Assist” (IMA) system’s electric motor operates in parallel with the engine, and only when needed. It adds a very noticeable extra 25 lb- ft of torque when accelerating hard from a stop or climbing steep grades at low to medium engine speeds. The electric motor is smaller than would be necessary if it was at any time the sole power source for the car. It’s only 2.3 inches wide, and mounted between the engine and transmission. It does triple duty, also serving as the engine’s starter motor and, under deceleration, generating power to recharge the nickel-metal hydride battery pack located underneath the rear cargo area. This regenerative braking also helps slow the car.

APPEARANCE: Remember the Honda CRX of a decade or so ago? The Insight looks like a CRX for the 21st Century. Like the CRX, it’s a tiny two-door fastback hatchback with a sleek, aerodynamic look and a horizontally-split rear window. Looks are not deceiving in this case, as form follows function. The Insight’s coefficient of drag (Cd) of 0.25 is one of the lowest of any production passenger car. This means that it requires less power to operate at highway speeds than a less aerodynamic car. The smooth shape is augmented by rear wheel spats which further reduce drag. >From the front, the Insight has a definite Japanese animation- inspired Honda face, with two complex headlights flanking a small unadorned air intake.

COMFORT: The Insight is small and light in weight, but not lacking in accommodation and comfort. It is, if anything, a bit upscale from a Civic hatchback in appointment, with plenty of S2000 influence. There is reasonable space for two people, with six-footers fitting easily into the twin sport seats. The instrument panel and steering wheel look right out of the S2000 roadster in design, and the Insight uses a liquid-crystal display (LCD) similar to that of the S2000. The LCD is well-shaded and easy to read, with a digital speed display and analog displays of tachometer, fuel level, engine temperature, and motor assist or charging. A locking glove box, net pocket behind the seats, and small console tray provide some storage for small items, and a picnic cooler-sized compartment beneath the rear of the rear cargo area will hold moderately-sized things out of sight. A ridge at the front of the cargo area helps keep things in their place, and there are tie-downs to secure cargo. Visibility is good to the front, sides, and directly to the rear, but, as is common with fastback designs, somewhat obscured to the rear quarters. Power windows, mirrors, and door locks with remote entry are standard.

SAFETY: The Honda Insight meets worldwide 2003 safety requirements. It has safety-cage construction with front and rear crumple zones, side-impact protection, dual air bags, and antilock brakes.

ROADABILITY: Despite its light weight, careful attention to aerodynamics keeps the Insight stable even at highway speeds in strong winds. Wind is noticeable, with attention on the driver’s part necessary (as is the case with all vehicles), but the Insight keeps to its intended path. Although its two-seat hatchback specification may sound like that of a small sports coupe, the Insight’s low- rolling-resistance tires are optimized for fuel efficiency, not cornering. It handles like a Civic, but the tires impose a relatively low limit on cornering fun compared to, say, a Civic Si. Still, it’s nimble, easily parkable, and no noisier than a Civic inside at any time. Thanks to a rigid, NSX-inspired aluminum-intensive structure, the Insight’s suspension is comfortably compliant. It uses the electric power steering system pioneered in the Acura NSX and also used in the Honda S2000. The front disc and rear drum brakes stop it quickly, and are aided by regenerative braking. When decelerating, the IMA electric motor acts as a generator. This recharges the battery pack and slows the car.

PERFORMANCE: Honda claims that the Insight’s 995cc three- cylinder engine is the smallest, lightest, and most efficient mass- produced automobile engine of its size. It weighs 124 lbs, and produces 67 horsepower at 5700 rpm and 66 lb-ft or torque at 4800 rpm. Lightweight materials and low-friction design contribute to its efficiency and power. Its single-overhead cam, 12-valve cylinder head uses Honda’s VTEC-E variable valve timing and lift system for increased efficiency and the ability to burn extremely lean gasoline/air mixtures for improved fuel economy and ultra-low exhaust emissions. The IMA electric motor’s extra 25 lb-ft of torque give the feel of a low-boost turbocharger. The Insight’s five- speed manual gearbox is designed to contribute to fuel economy. Both fourth and fifth gears are overdrives, so downshifting to third is necessary for climbing steep grades, even on the highway. Third is a near-direct drive, equivalent to fourth gear in most other gearboxes, and the lightweight Insight has no problem climbing steep grades in third gear. The Insight’s performance in everyday use is perfectly satisfactory, and while my average of 53 mpg was not the EPA estimated 61city, 70 highway range, it was hardly poor. That is real-world fuel economy, with hard acceleration in traffic and sustained 70-plus mph highway speeds in a hilly area.

Honda pioneered the use of aluminium body construction and it has used its experience with the NSX sports car to create a new type of lightweight aluminium body offering a high level of rigidity and safety performance. The Insight makes optimum use of a combination of extruded, stamped and die cast aluminium components and body weight is 40% less than a comparable steel body. All outer panels are aluminium except for the front wings and rear wheel skirt which are made from recyclable abs/nylon composite. Total kerb weight is 835 kg or 850 kg including air-conditioning.

Honda has also worked to provide the Insight with the best aerodynamic characteristics for a mass production car and design features include a streamlined nose, a low height and long tapered roof, narrow rear track, low drag grille, aluminium aero wheels, rear wheel skirt, a flat underside, and a tail designed to reduce the area of air separation. All features give the Honda Insight an aerodynamic drag coefficient (Cd) of 0,25.

SPECIFICATIONS
Dimensions: Length 3.945 mm, Width 1.695 mm, Height 1.355 mm, Wheelbase 2.400 mm
Engine Type single overhead cam 12-valve 3-cylinder
with VTEC-E Lean Burn and Integrated Motor Assist electric motor
Engine Size 1 liter / 61 cu. in. and  IMA permanent
magnet electric motor
Horsepower 67 @ 5700 rpm, 73 @ 5700 with IMA
Torque (lb-ft) 66 @ 4800 rpm, 91 @ 2000 with IMA
Transmission 5-speed manual
Wheelbase / Length 94.5 in. / 155.1 in.
Curb Weight 1887 lbs. with air conditioning
Pounds Per Horsepower        25.8
Fuel Capacity 10.6 gal.
Fuel Requirement unleaded regular, 87 octane
Tires P165/65 SR14 Bridgestone Potenza RE92
Brakes, front/rear vented disc / drum, antilock standard
(auxiliary braking provided by the
IMA electric motor in generator mode)
Suspension, front/rear independent MacPherson strut /
twist beam axle
Drivetrain front engine, front-wheel drive
EPA Fuel Economy - miles per gallon
city / highway / observed     61 / 70 / 54
0 to 60 mph 11  sec (est)