Chainsaw Chains 20 Inch: How to Switch to 16 Inch Bars (Pro Tips)

Introduction: Busting the “Bigger is Always Better” Myth in Chainsaw Bars

There’s a common misconception I often hear around the wood lot: “Bigger chainsaw bar, bigger the job you can handle.” While a 20-inch chainsaw bar certainly sounds more impressive than a 16-inch one, the reality is much more nuanced. In my years of experience felling trees, bucking logs, and prepping firewood, I’ve learned that the ideal chainsaw bar length isn’t about bragging rights – it’s about matching the tool to the task, and more importantly, to your skill level.

I’ve witnessed firsthand the struggles of folks wrestling with oversized chainsaws, struggling with control and ultimately compromising safety. On the flip side, I’ve seen others underestimate the potential of a well-matched, slightly shorter bar.

That’s why I’m here to debunk the “bigger is always better” myth and guide you through the process of switching from a 20-inch chainsaw bar to a 16-inch bar. We’ll explore the pros and cons, the technical considerations, and the practical benefits of making this change. I’ll share some of my personal experiences, industry insights, and step-by-step instructions to help you make an informed decision and execute the switch safely and effectively.

Key Takeaways You’ll Gain Today:

• Why size matters: Understand the impact of chainsaw bar length on cutting performance, user fatigue, and safety.
• Matching the bar to the job: Learn how to determine the ideal bar length for different types of wood processing tasks.
• The switcheroo: A detailed, step-by-step guide on safely removing a 20-inch bar and installing a 16-inch bar.
• Chain compatibility: How to select the correct chain for your new 16-inch bar.
• Fine-tuning and adjustments: Essential adjustments to ensure optimal performance and safety after the switch.
• Real-world benefits: How a shorter bar can improve maneuverability, reduce kickback, and enhance overall cutting experience.

Let’s dive in!

Chainsaw Chains 20 Inch: How to Switch to 16 Inch Bars (Pro Tips)

Understanding Chainsaw Bar Length: More Than Just Size

The length of your chainsaw bar dictates the maximum diameter of wood you can safely cut in a single pass. However, it’s crucial to understand that a longer bar doesn’t automatically equate to superior performance or increased efficiency. In fact, using a bar that’s too long for the job can lead to:

• Reduced control: A longer bar increases the leverage, making the chainsaw harder to control, especially for less experienced users.
• Increased kickback risk: The longer the bar, the greater the potential for the tip to catch and kick back, a leading cause of chainsaw injuries.
• Higher fatigue: Maneuvering a chainsaw with a longer bar requires more strength and stamina, leading to quicker fatigue.
• Slower cutting speed: Unless the saw has enough power, a longer bar can bog down the engine, resulting in slower cutting speeds.

Data Point: According to the Consumer Product Safety Commission (CPSC), chainsaw-related injuries result in approximately 28,500 emergency room visits each year in the United States. A significant portion of these injuries are attributed to kickback, often exacerbated by using an inappropriately long bar.

My Experience: I recall a time when I was helping a friend clear some storm-damaged trees. He insisted on using his brand-new chainsaw with a 24-inch bar, even though most of the trees were only 12-14 inches in diameter. He struggled to control the saw, constantly fighting the weight and leverage. After a few hours, he was exhausted and frustrated. When he finally let me use my trusty chainsaw with an 18-inch bar, the job became significantly easier and faster. This experience reinforced the importance of matching the bar length to the task and the user’s skill level.

Why Switch to a 16-Inch Bar? Assessing Your Needs

Before embarking on the switch, let’s examine the advantages of using a 16-inch chainsaw bar:

• Improved Maneuverability: A shorter bar makes the chainsaw lighter and easier to maneuver, particularly in tight spaces or when working on smaller trees and branches.
• Reduced Kickback Risk: With less bar tip exposed, the chance of kickback is significantly reduced, enhancing safety.
• Enhanced Control: A shorter bar provides better control, allowing for more precise cuts and reducing the risk of accidental damage or injury.
• Less Fatigue: The lighter weight and improved maneuverability translate to less strain on your body, allowing you to work for longer periods without fatigue.
• Ideal for Smaller Tasks: A 16-inch bar is perfect for limbing, pruning, cutting firewood from smaller logs, and general yard maintenance.

When a 16-Inch Bar Might Be the Right Choice:

• You primarily cut smaller trees and branches.
• You value maneuverability and control over maximum cutting capacity.
• You are a beginner or intermediate chainsaw user.
• You experience fatigue quickly when using a longer bar.
• You want to reduce the risk of kickback.

Expert Insight: “For most homeowners and occasional users, a 16-inch chainsaw bar offers the perfect balance of cutting capacity and maneuverability,” says Mark Johnson, a certified arborist and owner of a tree care company. “It’s a versatile tool that can handle a wide range of tasks without being overly cumbersome or dangerous.”

Preparing for the Switch: Gathering Your Tools and Supplies

Before you start, gather the necessary tools and supplies to ensure a smooth and safe transition:

• New 16-inch chainsaw bar: Choose a high-quality bar that is compatible with your chainsaw model. Refer to your chainsaw’s manual for the correct specifications.
• New chainsaw chain: Select a chain that matches the pitch, gauge, and drive link count of your new 16-inch bar. Again, consult your chainsaw’s manual for the correct specifications.
• Chainsaw wrench or combination tool: This tool is essential for loosening and tightening the bar nuts and chain tension.
• Screwdriver: You may need a screwdriver to adjust the chain tension.
• Gloves: Protect your hands from sharp edges and debris.
• Safety glasses: Protect your eyes from flying wood chips and debris.
• Clean rags: Use these to wipe down the bar and chain.
• Chainsaw bar oil: Lubricate the bar and chain to reduce friction and wear.
• Work gloves: Highly recommended to protect your hands.
• A safe work surface: A sturdy bench or table.

Important Note: Always disconnect the spark plug wire before performing any maintenance or repairs on your chainsaw. This will prevent accidental starting and potential injury.

Step-by-Step Guide: Switching from a 20-Inch Bar to a 16-Inch Bar

Now, let’s get down to the nitty-gritty of the switch. Follow these step-by-step instructions carefully:

Step 1: Safety First – Disconnect the Power

• As mentioned before, the very first thing you MUST do is disconnect the spark plug wire from the spark plug. Tuck it away safely so it can’t accidentally reconnect. This prevents any chance of the chainsaw starting unexpectedly.

Step 2: Loosen the Bar Nuts

• Locate the bar nuts on the side of the chainsaw, usually covered by a chain brake lever.
• Engage the chain brake.
• Using the chainsaw wrench, loosen the bar nuts. Do not remove them completely at this stage. Just loosen them enough so you can move the bar.

Step 3: Release Chain Tension

• Most chainsaws have a chain tensioning screw located near the bar nuts.
• Use the screwdriver or chainsaw wrench to turn the tensioning screw counterclockwise, reducing the tension on the chain. You want the chain to be loose enough to easily remove from the bar.

Step 4: Remove the Old Chain and Bar

• Disengage the chain brake.
• Carefully remove the bar nuts and the side cover.
• Lift the old chain off the bar, starting at the sprocket. Be careful of the sharp cutters on the chain.
• Slide the 20-inch bar off the mounting studs.

Step 5: Inspect and Clean

• Take this opportunity to inspect the sprocket, bar mounting surface, and oiler hole for any damage or debris.
• Clean these areas thoroughly with a clean rag. A build-up of sawdust and oil can affect the performance of the new bar and chain.

Step 6: Mount the New 16-Inch Bar

• Align the mounting hole on the new 16-inch bar with the mounting studs on the chainsaw.
• Slide the bar onto the studs, ensuring it sits flush against the chainsaw body.
• Make sure the tensioning pin on the chainsaw aligns with the tensioning hole on the bar.

Step 7: Install the New Chain

• Place the new chain over the sprocket, ensuring the cutters are facing in the correct direction (they should point forward on the top of the bar).
• Carefully guide the chain around the bar groove, starting at the top and working your way around.
• Ensure the drive links of the chain are properly seated in the bar groove.
• Bring the two ends of the chain together at the bottom of the bar and connect them.

Step 8: Reinstall the Side Cover and Bar Nuts

• Position the side cover back onto the chainsaw, aligning the holes with the mounting studs.
• Tighten the bar nuts finger-tight. Don’t fully tighten them yet.

Step 9: Tension the Chain

• Use the chain tensioning screw to adjust the chain tension. The chain should be snug against the bar but still able to be pulled around by hand.
• A properly tensioned chain should have about 1/8 inch of sag in the middle of the bar.

Step 10: Final Tightening and Check

• Once the chain is properly tensioned, tighten the bar nuts securely with the chainsaw wrench.
• Double-check the chain tension and ensure the chain moves freely around the bar.
• Engage and disengage the chain brake to ensure it is functioning properly.

Step 11: Lubricate the Chain

• Fill the chainsaw’s bar oil reservoir with high-quality chainsaw bar oil.
• Start the chainsaw (with the spark plug wire reconnected, of course!) and let it run for a few seconds to allow the oiler to lubricate the bar and chain.
• Check that oil is being dispensed onto the bar and chain.

Step 12: Test Cut and Adjust

• Make a few test cuts to ensure the chainsaw is cutting smoothly and efficiently.
• If necessary, readjust the chain tension and oiler flow.

Caution: Always wear appropriate safety gear when operating a chainsaw, including safety glasses, hearing protection, gloves, and sturdy boots.

Choosing the Right Chain for Your 16-Inch Bar

Selecting the correct chain for your new 16-inch bar is crucial for optimal performance and safety. Here are the key factors to consider:

• Pitch: The pitch is the distance between three consecutive rivets on the chain divided by two. Common chainsaw pitches are 0.325 inch, 3/8 inch, and 0.404 inch.
• Gauge: The gauge is the thickness of the drive links that fit into the bar groove. Common chainsaw gauges are 0.043 inch, 0.050 inch, 0.058 inch, and 0.063 inch.
• Drive Link Count: The drive link count is the number of drive links on the chain. This number is specific to the bar length and chainsaw model.

How to Find the Correct Chain Specifications:

• Consult your chainsaw’s manual: The manual will provide the exact pitch, gauge, and drive link count for your chainsaw model and bar length.
• Check the old chain: The pitch and gauge are often stamped on the drive links of the old chain.
• Use an online chain selector tool: Many chainsaw manufacturers offer online tools that help you find the correct chain for your chainsaw model and bar length.
• Ask a knowledgeable dealer: A reputable chainsaw dealer can help you select the correct chain and answer any questions you may have.

Example: Let’s say your chainsaw manual specifies a 3/8-inch pitch, 0.050-inch gauge, and 56 drive links for a 16-inch bar. You would then purchase a chain with those specifications.

Data Point: Using the wrong chain can lead to poor cutting performance, increased wear and tear on the bar and chain, and even damage to the chainsaw itself. Always double-check the specifications before purchasing a new chain.

Fine-Tuning and Adjustments: Optimizing Performance

After installing the new 16-inch bar and chain, it’s essential to fine-tune the chainsaw to ensure optimal performance and safety. Here are some key adjustments to consider:

• Chain Tension: As the chain heats up during use, it will expand and may become too loose. Check the chain tension frequently and adjust as needed. A properly tensioned chain should have about 1/8 inch of sag in the middle of the bar when cool.
• Oiler Flow: The oiler flow controls the amount of oil dispensed onto the bar and chain. Adjust the oiler flow to ensure adequate lubrication. Too little oil can lead to excessive wear and tear, while too much oil can create a mess.
• Carburetor Adjustment: If the chainsaw is not running smoothly or is difficult to start, you may need to adjust the carburetor. Consult your chainsaw’s manual for instructions on how to adjust the carburetor.
• Chain Sharpening: A sharp chain is essential for efficient and safe cutting. Sharpen the chain regularly using a chainsaw file or a chain grinder.

My Tip: I always carry a chainsaw file with me when I’m working in the woods. I sharpen the chain every time I refuel the chainsaw, which ensures that it’s always cutting at its best.

The Real-World Benefits: Enhanced Cutting Experience

Switching to a 16-inch chainsaw bar can significantly enhance your cutting experience, particularly if you primarily work on smaller trees and branches. Here are some of the real-world benefits you can expect:

• Improved Maneuverability: The lighter weight and shorter bar make the chainsaw easier to maneuver, allowing you to work in tighter spaces and with greater precision.
• Reduced Kickback Risk: With less bar tip exposed, the chance of kickback is significantly reduced, making the chainsaw safer to operate.
• Enhanced Control: The shorter bar provides better control, allowing you to make more accurate cuts and reduce the risk of accidental damage or injury.
• Less Fatigue: The lighter weight and improved maneuverability translate to less strain on your body, allowing you to work for longer periods without fatigue.
• Increased Efficiency: For smaller tasks, a 16-inch bar can actually be more efficient than a longer bar, as it allows you to make quicker and more precise cuts.

Case Study: A local firewood producer recently switched from using 20-inch bars to 16-inch bars on their chainsaws. They reported a significant reduction in operator fatigue and an increase in overall productivity. They also noted a decrease in chainsaw-related injuries.

Addressing Potential Concerns: Common Questions and Answers

Before we wrap up, let’s address some common questions and concerns about switching to a 16-inch chainsaw bar:

• Will a 16-inch bar be powerful enough for my needs? For most homeowners and occasional users, a 16-inch bar provides ample cutting power for a wide range of tasks. However, if you regularly cut large trees or logs, you may still need a longer bar.
• Will I need to buy a new chainsaw to use a 16-inch bar? No, you can simply replace the existing bar and chain with a 16-inch bar and chain that are compatible with your chainsaw model.
• Will switching to a shorter bar affect the lifespan of my chainsaw? No, switching to a shorter bar will not negatively affect the lifespan of your chainsaw. In fact, it may even prolong the lifespan by reducing strain on the engine.
• Is it difficult to switch chainsaw bars? No, switching chainsaw bars is a relatively simple process that can be completed in a few minutes with the right tools and instructions.

Maximizing Chainsaw Efficiency: Pro Tips for Wood Processing

Beyond just switching the bar, here are some additional pro tips I’ve learned over the years to maximize your chainsaw efficiency and get the most out of your wood processing:

• Keep your chain sharp: A dull chain wastes energy and increases the risk of kickback. Sharpen your chain regularly.
• Use the right bar oil: High-quality bar oil reduces friction and wear, extending the life of your bar and chain.
• Maintain proper chain tension: A properly tensioned chain cuts more efficiently and reduces the risk of derailment.
• Use proper cutting techniques: Avoid forcing the chainsaw through the wood. Let the chain do the work.
• Clean your chainsaw regularly: Remove sawdust and debris from the bar, chain, and engine to prevent overheating and damage.
• Store your chainsaw properly: Store your chainsaw in a dry, safe place to protect it from the elements and prevent accidental starting.

Conclusion: Making the Right Choice for Your Needs

Switching from a 20-inch chainsaw bar to a 16-inch bar can be a game-changer, especially if you primarily handle smaller trees, branches, or firewood. The improved maneuverability, reduced kickback risk, and enhanced control can make your wood processing tasks safer, more efficient, and less fatiguing.

Remember, the “bigger is always better” mantra doesn’t always hold true. Choosing the right chainsaw bar length is about matching the tool to the task and your skill level. By carefully assessing your needs, following the step-by-step instructions, and fine-tuning your chainsaw, you can unlock a whole new level of cutting performance and enjoyment.

So, take the plunge, make the switch, and experience the difference a well-matched chainsaw bar can make! You might be surprised at how much easier and more enjoyable your wood processing tasks become. Now, go forth and conquer those logs!

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