How to Measure a Chainsaw Bar: A Step-by-Step Guide

To measure a chainsaw bar, just take a tape measure and go from where the bar comes out of the saw to the tip of the bar, then round that number to the nearest whole inch. This is called the “cutting length” or “called length.”

In this article, you’ll learn exactly how to measure your chainsaw bar both with and without removing it. We’ll also go over why measuring it the right way matters, what tools you’ll need, and how to avoid mistakes when buying a replacement.

Why Measuring Your Chainsaw Bar Matters

Knowing your bar length helps you buy the right replacement and keep your chainsaw running safely and smoothly. Using the wrong size bar can affect performance or even damage your chainsaw. 

Whether you’re changing out the bar, replacing the chain, or just trying to match parts, this is a small step that saves time and headaches.

Here’s why it’s worth doing right:

• Helps you find the correct chain and bar replacements
• Prevents wear and tear on the motor
• Keeps cutting performance consistent
• Ensures your chainsaw is safe to use
• Helps you avoid compatibility issues with your saw

Tools You’ll Need

You don’t need much to measure your bar. Just a few simple tools:

• Tape measure or ruler
• Work gloves (for safety)
• Flat surface to set the chainsaw on
• Optional: socket wrench (if you’re removing the bar)

How to Measure a Chainsaw Bar

There are two ways to measure a chainsaw bar. One is quick and easy without taking anything apart. The other gives you the full length but involves removing the bar. Here’s how to do both.

How to Measure the Chainsaw Bar Without Removing It

1. Turn off the chainsaw. Make sure the chainsaw is off, unplugged, or has the battery removed. Let it cool down if it’s been used.
2. Lay the chainsaw on a flat surface. Set it down where it won’t roll or move around.
3. Find the base of the bar. This is where the bar comes out of the body of the chainsaw.
4. Measure from the base to the tip. Use a tape measure and go from the base (where the bar meets the housing) to the very tip of the bar.
5. Round to the nearest inch. If your measurement is 15¾ inches, just round up to 16 inches. That’s your “called length” or usable cutting length.

How to Measure the Full Bar Length (By Removing It)

If you want to know the bar’s actual length from end to end, you’ll need to remove it. Here’s how:

1. Put on gloves and make sure the chainsaw is off. Always work safely, even if you’re just measuring.
2. Remove the side panel or housing. Use a socket wrench or the tool your chainsaw came with to remove the side cover where the bar is mounted.
3. Take off the bar and chain. Carefully slide the bar and chain out of the body of the saw.
4. Measure the entire bar. Lay the bar flat and use a tape measure to measure from the very tip to the very back end, including the part that fits inside the saw.
5. Check for specs stamped on the bar. Most bars have the pitch, gauge, and drive link number stamped on them. These numbers are useful if you’re replacing the chain too.

Common Chainsaw Bar Sizes and Compatibility Tips

Chainsaw bars come in a range of sizes, usually from 10 inches up to 36 inches for heavy-duty saws. The most common sizes for home or light commercial use are 14″, 16″, 18″, and 20″. But it’s not just about the length—compatibility depends on more than just how big the bar is.

Here are a few tips to make sure your replacement bar fits your chainsaw:

• Check your saw’s manual or label for the supported bar length range.
• Match the bar mount type—each saw brand has its own mounting system.
• Consider the power of your chainsaw—a small engine won’t handle a large bar well.
• Double-check the chain specs—your new bar must match in pitch, gauge, and drive links.
• Stick to the same brand when possible to avoid compatibility issues, unless you’re using a universal-fit bar.

Measuring Tips for Replacing the Chain and Bar Together

If you’re replacing both the chain and bar at the same time, it’s important that all the parts work well together. Here’s how to avoid common mix-ups:

• Match the chain pitch and gauge to the bar. These are usually stamped on the old bar.
• Count the number of drive links on your chain or check the original packaging.
• Take note of the bar mount type—this affects whether it’ll even fit on your saw.
• Stick with the same bar length unless your saw supports a different size.
• Bring the old bar or chain to the store if you’re unsure about measurements.

What’s the Difference Between Bar Length and Chain Length?

Bar length is the part of the bar that sticks out of the chainsaw and is used for cutting, while chain length is determined by the chain’s pitch, gauge, and number of drive links.

It’s easy to confuse the two because people often assume a longer bar needs a longer chain, and while that’s true, the measurements are not interchangeable. Bar length is measured in inches from the front of the saw to the tip of the bar, rounded to the nearest inch.

Chain length, on the other hand, is all about how the chain wraps around the bar and sprocket. Even two bars of the same length can require chains with different drive link counts depending on how the bar and saw are built. 

Always check the pitch and gauge before buying a chain to match your bar.

When to Replace Your Chainsaw Bar

Even a well-maintained bar doesn’t last forever. Here are some signs that it might be time for a new one:

• The bar is visibly bent or warped—this can cause uneven cuts and dangerous kickback.
• The chain doesn’t sit properly in the groove—this could mean the groove is worn out.
• Deep burrs or sharp edges along the sides of the bar can snag the chain or cause binding.
• The bar tip is damaged or not spinning smoothly, especially important if you have a sprocket nose bar.
• Cuts are no longer straight—a worn bar often causes the saw to pull to one side.
• Frequent chain derailing—this may indicate the bar is no longer holding the chain correctly.

Conclusion

Measuring your chainsaw bar is quick, easy, and saves a lot of trouble down the line. Whether you’re replacing the bar, picking out a new chain, or just want to check compatibility, knowing the correct bar size helps you make the right choice. 

Start by measuring from the body of the saw to the tip of the bar, round to the nearest inch, and double-check any stamped specs if you’re removing the bar.

Taking a few minutes to measure things properly can help your chainsaw run smoother, cut better, and stay safe to use.

FAQs

Can I put a longer bar on my chainsaw?

Sometimes, yes—but it depends on your chainsaw’s power and design. Smaller engines can’t handle longer bars well. Always check your user manual to see the recommended bar length range.

How do I know what chain fits my bar?

Look for the pitch, gauge, and number of drive links—these are usually stamped on the old bar or printed on your saw’s label. All three numbers need to match when buying a new chain.

What does “drive link count” mean?

It refers to the number of links on the chain that sit inside the bar groove and wrap around the sprocket. Getting this number right is important for chain fit and tension.

Are bar measurements universal across brands?

Not always. Even if two bars are the same length, they might have different mount types or chain specs. It’s best to stick with the same brand or check for compatibility if using a different one.

Do electric chainsaws use different bar sizes?

Yes, many electric chainsaws use smaller bars—often 10 to 16 inches. But just like gas saws, they still need the right pitch, gauge, and drive link count to match the bar and chain combo.

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