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How To Cut Roller Chain

In this article, we guide you through the basics of how to safely and effectively cut or break roller chains provided by USA Roller Chain and Sprockets. USA Roller Chain and Sprockets stocks tools to cut chain, such as roller chain breakers as well as roller chain pullers. These tools break ANSI sizes #25–#240, C2040–C2160H, and ISO metric sizes 03B–56B. However, the safety notes and steps below are applicable to all roller chain.

Safety Notes:

When working with roller chain, it is important to exercise caution to avoid serious injury. Always consult your owner's manual for specific safety instructions for your particular make and model of chain. Breaking roller chain is a necessary but potentially dangerous task. To help ensure safety, it is important to have a few key notes in mind.

1. Always use the correct tools for the job.
2. Wear protective clothing, including gloves and eye protection.
3. Confirm there is zero tension on the roller chain. This may require a roller chain puller.
4. Verify all equipment with a roller chain is shut off and no longer powered.
Once the chain is broken, dispose of it properly to avoid injuries.

Breaking the Chain

Cutting Roller Chain Step 1

Clamp the Chain Breaker onto the rollers of the roller chain.

It is imperative to make sure that the tip of the roller chain breaker and pin of the roller chain are aligned exactly. If not, you may break the chain breaker tip or be unable to break the roller chain.

Cutting Roller Chain Step 2

Turn the handle clockwise to push the pin and break the rivet of the chain.

As you can see, the roller chain rivet has been broken. Some people choose to stop here and attempt to push the single pin out. This may work in some instances; however, we highly recommend against doing so as it is dangerous and difficult to do. Therefore, we recommend continuing on to step 3.

Cutting Roller Chain Step 3

Next, repeat steps 1 and 2 to remove the second pin from the connector plate.

After this step, your chain should look something like the photo below. Both rivets on that chain side are now broken, and you are ready to remove the pin link.

You Have Successfully Cut Your Roller Chain

Now that you have successfully cut your roller chain, be sure to clean and lubricate the newly exposed areas before putting it back together with a roller chain repair kit. If you are feeling unsure about how to take a link out of a chain, please consult a professional before attempting to do this yourself. Give us a call today or visit our website for our full line of premium-quality bearings, gearboxes/reducers, motors, pulleys, belts, and more. We also have an in-house fast-reaction machine shop for custom solutions.

Disclaimer: USA Roller Chain and Sprockets is not held accountable for any injuries and or cost associated to injuries and or equipment failure caused by improper use of roller chain or roller chain tools what so ever. We have published this page for informational purposes and to help people in the process of breaking a roller chain.

Phone: (407) 347-3519

Email: sales@usarollerchain.com