Harley Evo Cranks But Won’t Start [10 Proven Fixes]

One sunny afternoon, as I excitedly got ready for a long-awaited ride on my Harley Evo, I faced a familiar problem that bikers often encounter. 

I hopped on, turned the key, and tried to start the Harley, but it wouldn’t start. The engine cranked, but to my disappointment, it didn’t come to life. 

Then I researched and found out the possible solutions for it and fixed the issue with my Harley Evo.

In this article, we will dive into the possible solutions for why your Haley EVO cranks but won’t start.

Harley Evo Cranks But Won’t Start

A Harley Evo that cranks but won’t start can be quite frustrating for any bike owner. This issue can be traced back to several potential causes. 

It could stem from a faulty ignition system, a problem with the fuel delivery, or an issue with the engine’s compression. 

A dead battery or a defective starter motor could also be to blame. It’s crucial to perform a comprehensive check of all these components to pinpoint the source of the problem. 

By systematically diagnosing and addressing each potential cause, you’ll be on the path to getting your Harley Evo back on the road.

1. Dead Battery 

When your Harley Evo cranks but won’t start, one of the probable causes could be a dead battery.

A motorcycle battery, like any other battery, loses its ability to hold charge over time. 

If you’re encountering frequent starting problems, it’s a good idea to check the battery first.

To diagnose a dead battery, you’ll need a voltmeter. Here’s a step-by-step guide:

• Before starting, make sure the motorcycle is in the ‘Off’ position. This is to prevent any accidental shorts which can cause injury or damage to the motorcycle.
• Now locate the battery, usually located under the seat or behind a side panel. Refer to your motorcycle manual if you’re unsure.
• Attach the red positive lead of the voltmeter to the positive terminal on the battery and the black negative lead to the negative terminal.
• A healthy 12-volt motorcycle battery should be around 12.6 volts or higher. 
• If the reading is below 12.4 volts, your battery is undercharged. Below 10 volts means your battery is likely dead and needs to be replaced.

2. Spark Plug Issue 

Spark plugs are essential for igniting the fuel-air mixture in the engine’s combustion chamber. 

If a spark plug is worn out, dirty, or misfiring, it can prevent the engine from starting.

To diagnose a spark plug issue, start by visually inspecting the spark plug. Unhealthy spark plugs often have a build-up of deposits on their electrode or a cracked insulator.

How to Check the Spark Plug

• Remove the spark plug from the engine using a spark plug socket.
• Examine the spark plug for signs of wear or damage.
• Check the electrode (the small metal piece that the spark jumps from) for a build-up of deposit and the ceramic insulator for cracks.

If your spark plug is fouled or damaged, it will need to be replaced.

Replacing the Spark Plug

• Purchase a new spark plug. Ensure it’s the correct type for your Harley Evo model.
• Use a spark plug socket to remove the old spark plug.
• Insert the new spark plug into the hole. Gently tighten it with the spark plug socket, careful not to over-tighten.
• Reattach the spark plug wire.

After replacing the spark plug, try to start your Harley Evo again. If it still won’t start, other issues could be at play.

3. Fuel System Issue 

A common reason why your Harley Evo might crank but not start could be a fuel system issue. 

This can stem from various sources, such as a clogged fuel filter, faulty fuel pump, or dirty injectors.

The fuel filter is responsible for keeping impurities from the fuel out of the engine. Over time, these impurities can accumulate, leading to a clog. 

When this happens, fuel can’t reach the engine, and it won’t start. To fix this, replace the fuel filter regularly.

The fuel pump delivers fuel from the tank to the engine. If it’s not working properly, it can’t deliver fuel, and the engine won’t start. 

Listen for a humming noise when you turn the key to the “on” position. If you don’t hear this sound, your fuel pump might be the problem. 

You’ll need to have it inspected and possibly replaced by a professional.

Fuel injectors spray fuel into the combustion chamber. Over time, these can become dirty, affecting the fuel-air mixture and causing the engine to run poorly or not at all. Cleaning or replacing the injectors often resolves this issue.

4. Security System

The security system on Harley-Davidson motorcycles is designed to prevent theft and unauthorized use. 

However, it can sometimes cause your bike to not start even when the key is in the ignition. 

It’s vital to understand the operation and troubleshooting of Harley’s security system to avoid being left stranded.

Harley’s security system consists of a key fob and a security module. The key fob sends a unique code to the security module, which is expected to match the code programmed in the module.

If there is a match, the security system is disarmed, allowing the bike to start.

If your Harley Evo cranks but won’t start, the first thing to check is the key fob battery. 

A dead battery may prevent the key fob from sending the correct disarm signal. Replace the battery and check if the problem persists.

If the problem persists, try re-syncing the key fob and the security module. 

This process usually involves switching the ignition on and off in a specific pattern, then pressing a button on the key fob. Consult your Harley’s owner manual for the exact steps.

If all else fails, it might be an issue with the security module itself. In this case, a trip to the dealership or a qualified mechanic may be in order. 

They can use diagnostic tools to check the security system and repair or replace components as necessary.

5. Defective Starter Motor 

The starter motor plays a crucial role in igniting the engine; it uses electrical energy to rotate the engine’s flywheel.

 If the starter motor is faulty, it might not be able to perform this function adequately.

To diagnose a defective starter motor, listen for a clicking sound when you turn the ignition. 

This sound typically indicates that the starter motor is trying to engage but it’s unable to turn the engine over.

To verify this, you can perform a bench test. Remove the starter motor from Harley Evo and hook it directly to a battery. 

If the starter motor doesn’t rotate smoothly, this could be because of damaged brushes, bushings, or a poor armature. 

Should the starter motor be the issue, you will need to either repair or replace it. 

Some motorcycle enthusiasts opt to rebuild the starter motors, replacing worn components with new ones. 

However, if the damage is extensive, you might need to replace the entire motor. 

6. Fuel Pressure Issue 

The fuel system is vital in supplying the engine with the fuel it needs to run. 

When there’s insufficient fuel pressure, the engine won’t receive enough fuel, preventing it from starting. 

To diagnose the issue, examine the fuel lines, tank, carburettor, and connections for any signs of leakage. 

If you find fuel leaks, that could be a significant source of pressure loss. Replace any damaged components.

To accurately diagnose a fuel pressure issue, you’ll need a fuel pressure gauge. Connect it to the fuel system (usually at the fuel rail), and observe the reading while the engine is running. 

The pressure should be within the manufacturer’s recommended specs for your specific model. If it’s too low, it’s likely causing the problem.

If the fuel pressure is low, the cause could be a malfunctioning fuel pump or a clogged fuel filter. 

Inspect and test the pump and replace it if necessary. Replace the fuel filter as a part of this process, as a clogged filter can also lead to low fuel pressure.

The fuel pressure regulator ensures the pressure is maintained at the correct level. 

If it’s faulty, it can lead to pressure issues. Remove and inspect it for any signs of wear or damage. Replace if necessary.

7. Wiring Issue 

To troubleshoot the problem, you should inspect the bike’s wiring harness for any visible signs of damage or wear, such as frayed wires, loose connections, or burned insulation.

Start by disconnecting the battery. Then, carefully inspect all wires and connections within the harness.

 Look for signs of overheating, corrosion, or breakage. Ensure all connectors are firmly seated and not corroded.

If visual inspection doesn’t reveal the issue, you can use a multimeter to check for continuity. 

This will help you to identify any broken or shorted wires. Disconnect each wire at both ends before checking. 

If the multimeter shows an open circuit (no continuity), that wire might be the cause of the problem.

You can also use the multimeter to check the voltage supply to your ignition system. 

The voltage should be around 12V when the ignition is switched on. If it’s significantly lower, you may have a wiring issue or a weak battery.

If a faulty wire is identified, replace it with a wire of the same gauge and insulation rating. 

Make sure all connections are secure and properly insulated before reconnecting the battery.

8. Compression Issues

Compression issues are a common cause of a Harley Evo engine cranking but failing to start. 

To get why this happens, you need to know that a Harley Evo, like other four-stroke engines, needs the right mix of air and fuel in its cylinder. 

Then, it needs a powerful spark to light this mix at the correct time.

The entire process needs to occur under adequate compression. When compression is low, the mixture of air and fuel cannot be ignited properly, causing the issue.

When diagnosing compression issues, several components need to be inspected.

Firstly, check the condition of the pistons and piston rings, as worn-out ones can cause low compression. 

You can also do a compression test by inserting a tester into the spark plug hole and reading the PSI as the engine is cranked.

Secondly, inspect the intake and exhaust valves. Valves that do not open and close at the proper time or are damaged can lead to compression loss.

You should also examine the head gasket. A blown head gasket can cause low compression, and signs of this can be oil leaks, coolant leaks, or white smoke from the exhaust.

Lastly, the timing of the ignition system is crucial. If the spark fires either too early or too late in the compression stroke, the engine might crank but will not start.

9. Ignition System Issue 

The ignition system of the Harley Evo is crucial for starting the engine. If the bike cranks but won’t start, an ignition system issue might be the culprit. 

The spark plugs initiate the combustion process in the engine, and if they’re faulty, the bike won’t start. 

To check, remove the spark plugs and look for signs of wear or damage. If they’re coated in a black, sooty residue, they may be fouled and need replacement.

If that’s not the case, then check the ignition coil as it sends power to the spark plugs. If it’s faulty, the engine may crank but won’t start. 

Use a multimeter to test the ignition coil’s resistance levels. If they’re outside the specified range for your model, you’ll need to replace the coil.

You should also check the ignition switch, which is responsible for sending power from the battery to the rest of your bike. 

If it’s malfunctioning, it may not be properly distributing power, causing the engine to crank but not start. 

Check for loose or corroded wires, and test the switch with a multimeter to ensure it’s functioning correctly.

10. Crank Position Sensor Issue 

The Crank Position Sensor (CPS) plays a pivotal role in the functionality of a Harley Evo engine. 

It’s responsible for monitoring the engine’s speed and position and relaying this information to the engine control unit to manage ignition timing and fuel injection. A faulty CPS can prevent the engine from starting.

If your Harley Evo cranks but won’t start, the CPS could be the culprit. To diagnose the issue:

Locate the CPS

The Crank Position Sensor is typically located near the engine’s crankshaft. You might need a service manual for your specific model to locate it accurately.

Check for visible issues.

Once you’ve located the CPS, check for obvious issues like loose or corroded wiring. Sometimes, a simple cleaning or tightening can resolve the problem.

Test the CPS

If there’s no visible issue, test the CPS using a multimeter. Attach the multimeter to the sensor wiring and look for a reading. If the reading is inconsistent or non-existent, the CPS is likely faulty.

Replace CPS

If testing indicates a faulty sensor, you’ll need to replace it. Remove the old sensor, install the new one, and make sure it’s connected properly.