I sold my super dependable 2002 Lexus GS400 (one trip to the shop in 10 years), for a very miserly 2002 "Sebring Silver" Honda Insight. Same price... one you pay for luxury and the other you pay for fuel savings.
Anyway, the Honda Insight had a major service at the Honda dealer (on their dime) when I bought it.
1) new IMA hybrid battery pack ($3000 value)
2) new tires
3) ? new brakes... need to check on this via Honda service database
4) ? replace coolant... need to check on this via Honda service database
My Insight now has 140,000 miles... I've added 50K in just 12 months of commuting every weekend between Pensacola and Atlanta.
MAINTENANCE and REPAIR:
Link to Honda Insight Maintenace Interval list and Excel Spreadsheet: HERE
Just this week the idler pulley that tensions the serpentine belt started to whine, so a trip to the Autozone got me a new idler pulley wheel for $57. Took about an hour to change it out. Now, it's quiet as a baby again.
Link to idler pulley repair is on insightcentral.net forum with part #'s, etc.
I added last weekend an aftermarket Cruise Control. The total install time was about 7 hours. A second time would probably take 3, now that I figured it all out, and realize that most of the little parts that came with the generic cruise control kit are not used. Here's the DIY, step-by-step on the cruise control install at the InsightCentral.net website.
Some added thoughts on maintenance in the near future:
New Serpentine belt, at Autozone about $18
Coolant change, YouTube DIY video HERE
Make sure and use pre-mixed Silicate Free over-the-counter "Green", or Honda "Blue" coolant Type 2, P/N L999-9001. Uses about 2.5L for a normal "drain-n-fill" procedure.
Manual tranny fluid change, Genuine Honda MTF, about 1.6 quarts of oil. Link to InsightCentral thread
EGR valve replacement/cleaning and EGR plate clean-out: Links to EGR valve repair and rebuilt EGR valves here. EGR Plate cleaning DIY HERE
Another nice thread of pics cleaning EGR valve: HERE
EGR plate uses Honda Liquid Gasket
Spark plug replacement (they are "indexed" for each cylinder, so you must buy them from Honda)
Honda DOT 3 brake fluid replacement, recommended every two or three years. DOT 3 used in both brake and fluid clutch system, and about three 12oz bottles to flush both systems.
Brake bleeding using autobleeder (pics): HERE
Clutch bleeding procedure HERE
Valve lash adjustment, cold, .008" exhaust, and .007 intake". DIY LINKhttp://www.insightcentral.net/forums/honda-insight-forum-1st-gen-discussion/15976-valve-adjustment-proceedure-write-up-pics.html Can re-use gasket if you're careful not to damage it.
The valve clearance is: 0.007"-0.009" intake (closest to front of engine)
0.008"-0.010" exhaust (closest to firewall)