We have two Insights, both 2000 5spd.
Greysight, 186,000mi, factory replaced battery and latest module installed on Honda's nickle about a month ago; no obvious changes in power or mileage. Leaving a gas station with mpg indicator reset I can get low 70s if I get right on the freeway, stay in the slow lane and work all the hypermileage tricks. But if I have to do any stop and go or local driving, the average drops to very low 50s. When we got her all we could manage was high 40s no matter what, but cleaning the EGR valve a few times really helped.
Redsight, 132,000mi, new factory battery 100mi ago and latest module, all free from Honda. ($5600 invoice at Honda of Pasadena by-the-way) She gets about 43mpg no matter what. Probably should spend $225 on a new EGR valve and see if that helps, but hate to spend money without knowing...
Fuzzymutt, I like how you put it, "I think I'm in lean burn", because we don't really know. Your description is very good, yes I too find if I'm doing a steady 60mph they'll show some charging activity and the bar graph will sit below 50mpg and then I pull my throttle foot back just enough to send the bar graph up into the 100s. But being an idiot, I'd sure like to have a light!
On top of all this, we're looking for a new home for the Redsight as we're expecting twins next week and there's a new non-Hybrid Element in the driveway!
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