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 you with 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

    The wooden pellets are the first step to consider when smoked sausage is cooked on a pellet grill. Sure, wrapped meat doesn’t take long to cook, but you can still run out halfway through. When you’re sure about the quantity, you turn it on.

    Heat the grill until it gets to a temperature of about 500°F – 600°F. Once the grill is that hot, you should prepare your sausages.

    Place the sausage on the grill grate; make sure the links are not touching each other. Close the lid and allow the sausage to cook for 20 minutes.

    Monitor your sausage temperature, so it doesn’t overcook. However, you should ensure you are not opening the pellet grill all the time, so the grill doesn’t lose its heat.

    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.

    Recommended Products

    Old Wisconsin Premium Summer Sausage, 100% Natural Meat, Charcuterie, Ready to Eat, High Protein, Low Carb, Keto, Gluten Free, Beef Flavor, 8 Ounce
    • BEEF SUMMER SAUSAGE: OLD WISCONSIN Beef Summer Sausages are made from 100%, high-quality beef. Shelf stable and ready to eat
    • HIGH PROTEIN: Enjoy this 8 ounce OLD WISCONSIN Beef Summer Sausage as a high protein snack, as part of an on-the-go lunch or dinner or serve at holidays, birthdays, barbecues and get-togethers
    • LOW CARB SNACK: OLD WISCONSIN summer sausages are made in the USA and are an ideal keto snack food with zero carbs
    • PREMIUM BEEF QUALITY: Made with all meat — no binders, fillers or extenders — and is gluten free with no MSG added
    • NATURALLY HARDWOOD SMOKED: The unique, savory taste of OLD WISCONSIN summer sausages comes from a special blend of spices and smoked over real hardwood fires until it reaches perfection
    McCormick Pure Ground Black Pepper, 16 oz
    • McCormick Pure Ground Black Pepper delivers a sharp aroma & earthy heat
    • Always from premium, hand-harvested pepper
    • Pantry staple for seasoning in the kitchen and at the table
    • Blend into soups and stews
    • Livens up salads, vegetables, pasta, rice or potatoes

    About The Author

    Z Grills

    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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