Hark, yet another Clarity mode mystery (and my theory about what is going on): Iconless HV Mode.
You're cruising along with HV Mode disabled, proceeding under EV power. The EV icon is on and the ICE is off. Then the Clarity's EV range goes to zero and the battery gauge shows two bars. Refusing to delve into the forbidden two-bar zone, the Clarity starts its ICE in what I'm calling iconless HV Mode because the Clarity acts as if it was in HV Mode, but the HV icon does not appear.
I don't really consider this a mystery. It
might be a UI bug (or more likely just unclear design) in terms of what icons it shows, but all of my experience driving with an empty battery the behavior is as you described, which makes sense.
2 bars is "empty" as far as the car turning on the ICE goes. The deadband its battery management routine maintains is relatively narrow, such that if you regen a bit, or the ICE runs for a bit while at low speeds, you end up with a little excess energy in the battery, which will be used either when accelerating, or, if you baby it, to cruise at low speeds for a short distance. This is actually extremely similar to how a Prius or other mild hybrid works, you just don't see the battery state of charge in those vehicles so it's invisible.
It's possible your car is behaving differently from what I've observed, but assuming the behavior is similar you could think of it like this: The ICE has a minimum speed it can run, and therefore a minimum amount of power it can generate regardless of what the wheels are using. Additionally, it probably runs most efficiently, in terms of generating electricity, at some level above idle. Third, if it starts up and is cold, it will run for a minimum period of time to get up to temperature before it will turn off; I'm assuming though have not observed that there's some additional hysteresis such that if it turns on once warm it will stay on for at least some number of seconds minimum.
The car, therefore, presumably aims to run the ICE at an efficient point as necessary and possible. At highway speeds on a flat or mild-to-moderate uphill, this basically results in it linked to the wheels and running at a roughly constant speed. At slow or stop-and-go driving, this may result in the ICE running for a little bit, adding a few % charge to the battery along with regen braking, which then results in the ICE not necessarily turning on right away when you start moving again.
This all makes sense, works, and probably operates as designed, and becomes visible to the user through the blue area of the energy gauge moving around. But because you can't see precisely what the car is doing or why it's making its decisions, it appears somewhat random. The algorithm maybe seems clearer to me because I'm a power control systems programmer by trade, so I kind of have an intuitive sense of what it's doing behind the scenes.
I think a lot of what people perceive as "mysterious" is really a combination of unclear UI design (calling it "HV Charge" vs "Mountain Mode", having the white area on the power gauge indicate ICE start up in
some modes but not others), providing a mix of too much and too little information to the driver, and people trying to overthink or second guess fairly complex energy management software routines that--if you ignore them--"just work". If the UI provided no information, you wouldn't notice--like a regular ICE or most mild hybrid vehicles. You'd just drive and notice the ICE did things. If it provided way more info, you'd know what was going on, but drivers who didn't care (my wife, say) would be confused and intimidated by it. Honda picked somewhere in between, which is enough to make me happy (though I
really wish there were units of kW on the power gauge) but apparently is confusing for some drivers.
Y'all are forgetting one important point: It all depends on local prices.
If we're talking about pure economics what you say is true--if you have really expensive electricity and really cheap gas, it might indeed be cheaper to run all-gas all the time. You should keep in mind that oil changes and engine service aren't free, so gas miles have additional costs past just the price of fuel. (As, technically, does EV if you factor in battery pack degradation, but then you'd need to factor in ICE wear as well.)
But for myself, at least, the ecological and noise benefits of running all EV outweigh the price advantage even if gas is cheaper, and it seems likely to me that is going to be the case for some fraction of people who have spent the money for a Clarity. If price were the only thing you cared about and gas were that cheap where you live, why the heck wouldn't you just buy a cheaper non-plug-in mild hybrid?
For me of course that's not the case anyway. Gasoline is well over $4/gallon and power at home during off-peak is under 10 cents/kWh, so EV would be way cheaper even if I didn't have solar (which I do, so as you mentioned the incremental cost of electric fuel for driving is literally zero).