How To Grill Sausage On a Pellet Grill

how to grill sausage

Grilled sausage link is one of the most laid-back meals to prepare. For many people, slapping the sausage onto the grill and waiting for it to get done is the way. But the result is grilled sausages that are burnt and dry. But if you want the perfect links, you’ll have to do a bit more. Don’t worry; we’ll tell you what to do.

To cook the perfect bbq sausage, there are a few things you’ll need:

This guide will provide all the information you’ll need when grilling bbq sausage on a pellet grill.

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    What Are The Best Sausages For Grilling?

    One good thing about sausages is the options. There are many types of links you could choose from. The most common ones are usually beef or pork, but chicken sausages aren’t bad. You can use any of them for the perfect grilling.

    However, you need to pay attention to the lean-to-fat ratio of your sausage. If you choose too lean links, they become too dry after grilling. Also, if your grilled sausage is fattier, it becomes gritty and too hard to consume.

    When shopping, ensure you pay attention to the product’s label. Most times, the fat and lean percentage are written there. We recommend going for bbq sausage with an 80/20 percent lean to fat ratio to get the best results.

    best sausage

    How To Grill Sausage On A Pellet Grill

    Choosing the Right Sausage

    Before you start grilling, it’s important to choose the right type of sausage. There are many different types of sausage available, from spicy Italian sausage to sweet breakfast sausage. Here are a few things to keep in mind when selecting your sausage:

    – Choose high-quality sausage: Look for sausage that is made with high-quality ingredients and has a good balance of fat and meat.

    – Consider the casing: Some sausages come in natural casings, while others are made with synthetic casings. Natural casings can add a nice snap to the sausage, but they can also be more delicate and prone to breaking.

    – Think about the flavor: Consider the flavor profile of the sausage and how it will pair with your other ingredients. For example, spicy sausage can add a nice kick to a dish, while sweet sausage can complement the flavors of grilled vegetables.

    Preparing the Sausage

    Once you’ve chosen your sausage, it’s time to prepare it for grilling. Here are a few tips to help you get the most out of your sausage:

    – Let the sausage come to room temperature: Take the sausage out of the refrigerator and let it sit at room temperature for about 30 minutes before grilling. This will help it cook more evenly.

    – Prick the sausage: Use a fork to prick the sausage all over. This will help release any excess fat and prevent the sausage from bursting while it cooks.

    – Brush with oil: Brush the sausage with a little bit of oil to prevent it from sticking to the grill.

    Grilling the Sausage

    Now that your sausage is prepped and ready to go, it’s time to start grilling. Here’s how to grill sausage to perfection:

    – Preheat the grill: Preheat your grill to medium-high heat. About 500 °F.

    – Place the sausage on the grill: Place the sausage on the grill and cook for about 4-5 minutes per side, or until it is browned and cooked through. Use tongs to turn the sausage over halfway through cooking.

    – Check the internal temperature: Use a meat thermometer to check the internal temperature of the sausage. It should reach 160°F (71°C) for pork sausage and 165°F (74°C) for chicken or turkey sausage.

    – Let it rest: Once the sausage is cooked, remove it from the grill and let it rest for a few minutes before slicing. This will help the juices redistribute and keep the sausage moist.

    How Long To Grill Sausage

    Different sausages on the grill take varying amounts of time to get to perfection. But generally, Your smoked sausage should be done in 15 – 20 minutes when cooking under 550°F.

    Ensure to check the sausage’s internal temperature to remove any doubt about your grilled sausage being undercooked or not.

    Internal Temp Of Sausage

    When cooking BBQ sausage, you should grill your dish until it reaches an internal temperature of 165°F. Use an instant-read thermometer to measure your sausage temperature. You should insert it from one end of your grilled sausage, then run it towards the center.

    How To Tell If Sausage Is Cooked

    One of the easiest ways to check is to note the sausage done temp using a thermometer. The smoked link ready to serve must reach a sausage temperature of about 165°F.

    If you couldn’t get a thermometer, you could also check whether your smoked sausage is ready with a fork or knife. Open your grill, insert the cutlery into your link without slicing it into halves and hold it there for 10 -15 seconds. Remove the fork and place it on your tongue or lip. You could also touch it with your fingers.

    An undercooked grilled sausage will be cold when felt. However, this method is less effective, especially if you have little or no experience with the grill.

    We recommend sticking with the instant-read thermometer if you are new to the grill. Once you have smoked a few times, checking with a fork will be easier.

    Grilled Sausage Recipes

    Just as you have different kinds of sausages to consider, there are also other recipes to go with them. Didn’t we just show you a recipe? Well, that was the most basic of recipes. Some chefs won’t even count it as one.

    Some fantastic recipes have sausages in them. We think you would enjoy a few of them. While every recipe has its specific ingredients, there are some that you should always have on hand.

    • First is the Meat:Without one, you can’t have a grilled sausage recipe. The method of grilling and sausage temperature needed may differ in the recipes. Sometimes, even the sausages used may be different.
    • The Next Is Spices: Most recipes have some of these ingredients. Spices like garlic powder, ground mustard, fennel seed, and coriander.

    Their quantities would be dependent on the amount of sausage you are working with. Some sausage recipes would also need onion powder, black pepper, fresh minced leaves, and cutting table salt.

    You should be ready for anything the recipe throws at you with these ingredients. We have found some grilled sausage recipes specific to different sausages for you. Check them out as you perfect that sausage on the grill.

    What To Make With Grilled Sausage

    This section is essential if you want your grilled sausage as a menu item for yourself and your guests. You will need to put some food items together with your link to make the best eating for your friends.

    The most common dish involves stuffing your smoked sausage into a bun. This bun gives your link a balance of softness and sturdiness. But if you want some variety, we’ve got you covered.

    Here are some dishes that you can make with your grilled sausage:

    1. Sausage Sandwich

    You will need to get a French baguette for this grilled sausage recipe. Seasonings like red ball pepper, salt, sweet onions, olive oil, and jalapeno peppers are also needed. The sausage type doesn’t matter; A chorizo or kishka sausage will do.

    Mix your seasonings into the olive oil. Place your link, baguette, and seasoning mix on the grill. Smoke them for a short while at the right sausage temperature, then place your sausage into the baguette. Pour your seasoning mix into it, and your dish is ready. To spice things up, consider drizzling ketchup or mustard on it.

    Sausage Sandwich

    2. Turkey Italian Sausage

    The turkey Italian sausage comprises natural turkey and Italian sausage, all stuffed into a bun. Its recipe includes some ingredients like bell pepper, onions, tomato sauce, and cheese.

    When creating this dish, the first step will be caramelizing your onions by boiling them in a skillet with salt and pepper until it turns caramel. Make a mix with the seasonings and tomato sauce for your grilled sausage and turkey in the bun. Pour the onions and the mixture on the dish, and it’s ready to serve.

    Turkey Italian Sausage

    3. Sausage Balls With Cream Cheese

    This dish is excellent to add to your appetizer lists when preparing your BBQ sausage menu. Sausage balls consist of four primary ingredients, cheddar cheese, baking mix, cream cheese, and the sausage on the grill. Mix, roll, and grill them, then your delicious ball is ready.

    Sausage Balls With Cream Cheese

    4. Sausage Bacon

    You will need ingredients like fennel seeds, thyme, ground black pepper, dried parsley, ground pork, and apple vinegar to make this dish. Put the dried seasonings together and grind. Mix the ground seasonings, pork, and vinegar until they are well combined.

    Get six slices of bacon and apply your mix to them. Place the grilled sausage in the middle of the sliced bacon and wrap them together. Grill for a short time. Make a glaze from Worcestershire sauce and honey. Apply it to the dish, and it’s ready to serve.

    Sausage Bacon

    5. Sausage Bread

    Sausage bread is one of our all-time classics involving your grilled sausage and bread rolls. The best recipes for this side dish require key ingredients like mustard, ketchup, and buttery brioche.

    The sausage bread offers you a quick and tasty way to serve sausages. To get that crispy taste on this side dish, we recommend you grill the sausage bread on the pellet grill for some time.

    Sausage Bread

    Pro Tips

    When cooking the perfect smoked sausage, one thing to note is the pellet wood. The sausage temperature is essential, but the wood pellets that bring that heat are also crucial.

    We recommend you go for the ones with flavor because they work best with your BBQ sausage. The most popular flavored pellets you could work with are apple, cherry, hickory, maple, and pecan.

    Ensure your sausage is cold before grilling. Get it from the refrigerator and allow it to defrost for a few minutes only. Smoke is attracted to cold surfaces, so cooking chilled sausage on the grill gives it that smokey taste.

    Another tip we would recommend is for you to finish with a sear as looks matter also. You can sear the BBQ sausage on your grill or with a searing pan for a few minutes on each side to give it that pro look.


    Now, you are ready to cook the perfect sausages that everyone would want to have a bite from. Your pellet grill shouldn’t be for smoking meat only.

    Speaking of grills, you should know we stock the best. At Z Grills, we offer a wide range of pellet grills and accessories to suit your needs.

    You just have to order, and we’ll deliver to you within three to seven business days. Check us out today, and let’s make the perfect sausage together.


    Q: What type of sausage should I choose for grilling?

    A: Choose high-quality sausage that is made with good balance of fat and meat. Consider the casing and flavor profile of the sausage.

    Q: How should I prepare the sausage for grilling?

    A: Let the sausage come to room temperature, prick it with a fork, and brush it with oil to prevent sticking.

    Q: How do I grill sausage to perfection?

    A: Preheat the grill to medium-high heat, cook the sausage for about 4-5 minutes per side, turning it over halfway through cooking. Use a meat thermometer to check the internal temperature, which should reach 160°F (71°C) for pork sausage and 165°F (74°C) for chicken or turkey sausage. Let the sausage rest for a few minutes before slicing to keep it moist.

    Q: What are some serving suggestions for grilled sausage?

    A: Grilled sausage can be served on a bun with condiments, added to pasta with sauce and vegetables, made into a skewer with vegetables, or served with grilled vegetables like zucchini, eggplant, and asparagus for a healthy meal. The possibilities are endless!

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    About The Author

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    Z Grills

    Z Grills is a grill manufacturer with over 30 years of experience within the industry. With over 650,000 pellet grills sold and 85 million cooks made, trust us.

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