Rotary bending fatigue tests were carried out using both plain and notched specimens of a low-carbon steel with two different grain sizes (1 5 and 50 pm). The process of early crack development was observed by the replication method. The effect of grain size on crack development was studied.The main conclusions were as follows. (I) Fatigue resistance, in terms of the relative positions of the S-N curves, increases with decreasing grain size. This phenomenon is related to the number of cycles to propagate a crack to failure and the condition for the non-propagation of a fatigue crack. (2) The size of a non-propagating crack, which initiates below the fatigue limit, tends to become larger as grain size increases.(3) The difference in fatigue behaviour between small (15pm) and large (50pm) grain sized specimens is due both to a decrease in crack propagation rate and a smaller non-propagating crack limit in the finer grained material.