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Front Disc Brakes
The front brake single piston calipers fitted to the Insight are made from aluminum. This helps to reduce the weight and drag of the components significantly without a loss of strength in the components.
There are many other new design features which include:
Rear Drum Brakes
The Insight has a new two piece rear drum design with aluminum fins. The internal brake surface is made of conventional cast iron to help achieve a stable fraction, while the rest of the drum is made of aluminum which has large finning around the outer edge. This design has significantly reduced weight over a cast iron drum. The use of aluminum fins on the outside helps to assist with cooling.
While a typical cast iron drum might weigh 3.4 kg (7.5 lbs.), the Insight's aluminum/cast iron drum weighs 2.1 kg (4.6 lbs.). The drum's outside diameter is 181 mm.
Anti-Lock Braking System
The Insight is equipped with a compact and lightweight ABS modulator assembly. The modulator unit and ABS control unit are integrated into one component which also includes relays, wires and electrical couplers.
During ABS function the IMA cuts battery regeneration (charging) to ensure there is adequate voltage for ABS operation. After ABS operation has ceased, the IMA recommences battery regeneration (charging).