Hi I'm running my Insight Gas Only successfully right now. I've only been doing it for a couple thousand miles, but so far it's working very well.
I've just had my HV battery pack die at 141k miles. 2 Error codes: P1447, P1449. FSManual says they mean Battery Deterioration / Overheating. The overheating makes sense if some or all batteries shorted-out. Solution offered is: "Replace Battery Pack".
Called Honda Dealer for Replacement parts while still driving to work 122 miles a day round-trip. Insight Central and Honda say '00-'02's may need the BCM & MCM replaced as well as the NiMH battery pack.
Battery Pack = $1,972.56
Battery Control Module (BCM) = $1,860.08
Motor Control Module (MCM) = $845.15
Freight (shipping) = $465
Total = $5,142.79
Sounds crazy, but I called and these were the Honda Dealer quotes. They DID say that's worst case scenario and just replace the battery pack first, just in case the rest are ok and don't need replacing.
During the 2 days I was gathering quotes, I was running gas only and getting BETTER gas mileage by 2-ish mpg...! I was EXPECTING worse mpgs! This opened my mind a bit, because I'm really more beholden to getting good gas mileage (50+ mpg) than having or not having batteries. (I'm an old CRX-HF guy and I've always hoped Honda would re-release these simple wonderful cars. Call 'em "Honda Lites"... or something)
After the sticker-shock, I searched Google / Insight Central for anyone who has converted their Insights to Gas Only, and finally I found THIS THAT WORKS from Mike Dabrowski and Friend. (I'll go into more detail below it to fill in any blanks):
-----------------------
Originally Posted by Mike Dabrowski 2000
Some new and interesting information about this subject.
A guy that bought the last MIMA system has an Insight he has been driving without the IMA pack. Here is what he had to say:
"I am presently replacing my battery pack, so I am using the Insight as a
pure-gas car right now. You might find it interesting that the remaining IMA components will keep the 12V battery charged with the High-voltage battery pack removed, so long as the BCM low voltage connector is also disconnected and the MCM remains fully connected. The only catch is that when engine RPM exceeds 4000, the 12V battery charging is temporarily suspended"
-----------------------------------------------
With this in hand and my FSManual, I opened the IPU up, and literally just disconnected ALL 3 connectors to the BCM (Battery Control Module) so that it is not connected at all. I left EVERYTHING else alone/completely hooked up.
That's it. I haven't tried to save weight by removing the battery pack itself yet, because frankly the wires to the MCM are integrated into the battery pack housing, and I'm taking this is steps.
On my test drive I experienced the Battery Light and E-Brake Light coming on simultaneously for "25-mississippi" and then go off. I was a ways out, so I nearly had a heart-attack. I've come to learn that it's exactly as the fellow said above. The MCM is managing the 12v Battery, but over 4,000 rpms the lights come on for 25-ish seconds and then goes out again. It's the battery charging cutting out. YES, it's more pokey than with batteries, but I just use the VTEC cam when I need "get-up-and-go".
Anyway, fingers crossed, but I'm saving the $$$ and running gas only for as far as this awesome little car will carry me. Oh, and I'm getting 62.2 avg mpg per tank where I couldn't get 59 with batteries on this particular run... and I've been trying this run since last August so I've had lots of practice. ONE HAND tied behind it's back, the Insight's still the MPG KING.
Hope this helps anyone in my (former) predicament -or- who wants to know if Insights without batteries are still any good. So far... they're BETTER. who knew?
Thanks to Mike Dabrowski, Insight Trekker, IAMIAN, etc. I've been reading your stuff here and at 99mpg.com for 3 years I'm a big fan.
Most Sincerely
Gene V.