While I understand and accept the 68hp 1.0L 3 cylinder engine, the 5 speed manual transmission gearing is a joke. To get to 2nd gear at 2000rpm, you must shift at 4000rpm in first gear!
A member from Insight Central figured out that 1st gen Honda Civic Hybrid (HCH) manual transmission housing is the same casting as the Insight transmission, and that the 1st gen Honda Fit manual transmission gear set will fit inside the HCH casting. He basically put all gears and differential from the Fit into the HCH transmission, with the 4.29 FD and all. That gave me the idea of just using the HCH manual transmission as-is as it has closer 1st to 2nd gear ratio and a shorter final differential ratio (3.6 of HCH vs 3.21 of the Insight).
A few minor modifications later, the HCH transmission is installed in my Insight. It's now only a little over 3000rpm in first to get to 2000rpm in second. I can use second gear between 10-18mph without lagging the engine. Acceleration is improved in all gear and feel way more than 12% as the FD ratio suggest. The car can climb small incline in 5th gear now on highway! It requires way less downshift just to maintain speed. My IMAless gas Insight actually feel FUN to drive!
What about MPG? Constant 45mph with 6 stops got me.
A member from Insight Central figured out that 1st gen Honda Civic Hybrid (HCH) manual transmission housing is the same casting as the Insight transmission, and that the 1st gen Honda Fit manual transmission gear set will fit inside the HCH casting. He basically put all gears and differential from the Fit into the HCH transmission, with the 4.29 FD and all. That gave me the idea of just using the HCH manual transmission as-is as it has closer 1st to 2nd gear ratio and a shorter final differential ratio (3.6 of HCH vs 3.21 of the Insight).
A few minor modifications later, the HCH transmission is installed in my Insight. It's now only a little over 3000rpm in first to get to 2000rpm in second. I can use second gear between 10-18mph without lagging the engine. Acceleration is improved in all gear and feel way more than 12% as the FD ratio suggest. The car can climb small incline in 5th gear now on highway! It requires way less downshift just to maintain speed. My IMAless gas Insight actually feel FUN to drive!
What about MPG? Constant 45mph with 6 stops got me.
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