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Gas Grill Troubleshooting Guide

Last updated on Jun 3, 2025

Whether you're running a catering operation, prepping for a tailgate event, or managing a commercial kitchen with outdoor service, a gas grill is a vital tool for high-volume, high-efficiency cooking. However, even the most reliable grills can encounter issues, from weak flames and ignition failures to uneven heat distribution or sudden shutdowns. We've compiled a list of common gas grill problems and their resolutions to keep service smooth and the grill running when it matters most.


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Use the following links to troubleshoot your gas grill:

  1. Gas Grill Has a Low Flame
  2. Gas Grill Won't Light
  3. Gas Grill Won't Stay Lit or Keeps Going Out
  4. Gas Grill Has Yellow or Orange Flames
  5. Gas Grill Is Not Getting Gas
  6. Gas Grill Is Producing Too Much Smoke
Restaurant Equipment

Gas Grill Has a Low Flame

A low flame can make it difficult to reach proper cooking temperatures, often resulting in undercooked food. This issue may be related to gas flow restrictions or regulator problems.

  • Propane tank is low or nearly empty. Refill or replace the propane tank.
  • Regulator needs to be reset. Turn off the gas at the tank and disconnect the hose. Turn all burner control valves to HIGH for one minute to purge any air, then turn them OFF and wait five minutes for any gas to clear. Reconnect the hose, slowly open the tank valve, and relight the grill as usual.
  • Clogged burner ports. Ensure there is no debris or spiderwebs inside the burners, or burnt-on grease or food on the exterior, as they can clog the ports. Make sure the gas is turned off before removing the burners and use a stiff wire brush to clean them.
Restaurant Equipment

Gas Grill Won't Light

A grill that won’t light or stay lit can indicate issues with gas flow, ignition components, and blockages. This is a common issue that can often be quickly diagnosed.

  • Empty or improperly connected propane tank. Ensure the tank is full and the valve is securely connected.
  • Gas supply is turned off. Turn on the gas supply.
  • Dead or dirty igniter. If you have an electric ignitor and there is no clicking, or the clicking is slow or faint, replace the battery. Carefully clean the ignitor if it's clogged or replace if it's damaged.
  • Blockage in the gas system. Inspect the burners to be sure insects, spider webs, and rodent nests do not block them. Clean if necessary. Inspect the control panel to be sure the burners are aligned properly with the valves.
  • Crimped or damaged fuel supply hose. Inspect and straighten or replace.
  • Grill is in bypass mode. Turn off all burners, reset the regulator, and then slowly open the tank valve.
Restaurant Equipment

Gas Grill Won't Stay Lit or Keeps Going Out

A grill that won’t stay lit may indicate airflow, gas supply, or component issues. It often starts and then goes out within seconds or minutes.

  • Low fuel levels. Low fuel levels in the tank can lead to weak or sputtering flames. If the propane tank is nearly empty or malfunctioning, it is recommended to refill the tank with more propane or replace it entirely.
  • Wind is blowing out the flame. Reposition the grill away from the wind or use a compatible wind guard.
  • Clogged burners or venturi tubes. Clean the burners and ensure tubes are free from any obstructions.
  • Faulty regulator. Try resetting the regulator or replace if necessary.
Restaurant Equipment

Gas Grill Is Not Getting Gas

If your gas grill isn’t getting any gas, there are several possible causes. Here are some steps to help you identify and fix the issue:

  • Check the propane tank or natural gas supply. Ensure that the propane tank is adequately filled or verify that the shut-off valve on the gas line is open and that the line has sufficient pressure. Additionally, confirm that the tank or gas line valve is fully opened.
  • Reset the regulator. The regulator may be in bypass mode, which restricts gas flow.
  • Check for hose blockages. Look for kinks, cracks, or damage in the hose that could block flow. 
  • Check for gas leaks. Use a 50/50 solution of soap and water on the hose and other connection points to check for a leak. If bubbles form at any of the points, you’ve got a leak.
  • Burners are clogged or misaligned. Clean out any debris or food buildup and realign burners with the valves if necessary.
Restaurant Equipment

Gas Grill Has Yellow or Orange Flames

Often, yellow or orange flames indicate an issue with the burners or venturi tubes. The good news is that these issues are usually related to spiderwebs and other blockages or a misalignment of the burners, which are all easy fixes.

  • Venturi tubes are blocked. Check for debris or pests and clean.
  • Burners have a high buildup of grease or dirt. Remove and clean the burners with a stiff wire brush.
  • Burners are not aligned properly with the valves. Inspect and realign if necessary.
  • Malfunctioning regulator. Reset your regulator or replace it.

 

Restaurant Equipment

Gas Grill Is Producing Too Much Smoke

If your gas grill is producing too much smoke, it’s usually due to leftover grease, food residue, or flare-ups from excess fat. Grease buildup on the burners or drip pan can burn off during use, creating thick smoke and unpleasant odors. Dirty grates or leftover food particles can also contribute to the issue, especially if the grill hasn’t been cleaned after previous sessions.

To reduce smoke, clean the grill thoroughly, paying attention to the exterior, cooking grates, grease tray, and burners. The grease tray should be cleaned after each use, while components like the burners can be maintained less frequently. Regularly cleaning your grill prevents grease from building up, which effectively lowers the risk of grease fires and flare-ups.

By following the troubleshooting tips in this guide, you can quickly pinpoint and resolve common problems with your outdoor grill. Start by checking the basics - ensure there's enough fuel, inspect for blockages in key components and connections, and look for any grease buildup that could affect performance. Regular maintenance and routine inspections go a long way in extending your grill's lifespan and keeping it running smoothly. By addressing issues promptly and following manufacturer guidelines, you can enjoy a seamless grilling experience every time.

The information provided on this website does not, and is not intended to, constitute legal advice. Please refer to our Content Policy for more details.

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