Char Broil Grill Flame Problems [Solved A-Z]

The most common Char Broil grill flame problems are usually either the flame being too low or too high. There are many reasons behind it. But more often than not, it’s a tripped gas regulator.

You can easily fix the issue by resetting this gas grill regulator. But if that’s not the problem, I have written in detail about what could be the issue. Just go through them one by one, and you’ll be fine. Let’s dive in!

Char Broil Grill Flame Problems [Solved A-Z]

If you’re wondering why there are flame issues in your Char Broil grill, here are the main reasons behind it, along with the right solutions.

1. Tripped Gas Regulator

The number one reason why you face the Char Broil grill low flame problem is when the gas regulator is tripped. I mean, there’s also the possibility that you’re out of gas. But I am going in with the assumption that you’ve already checked for that and made sure there is a proper gas supply.

Now, the job of the gas regulator is pretty simple. As the name suggests, it restricts gas flow when there’s a gas leak. There’s a pressure sensor in there to do this, and it mainly works as a safety device.

But sometimes, there are false alarms, and if you are new to using these heaters, let me tell you that it happens more than you might think. But sometimes, this grill regulator gets tripped due to not following the right startup procedure when turning on the grill.

If you accidentally turn on the grill knobs on before you open the LPG tank valve, the gas regulator gets tripped. In that situation, you won’t get proper heat from the grill. It can reach a maximum of 250 to 300 degrees Fahrenheit even if you put all the burners on a high setting.

Solution:

If the gas regulator is already tripped, you need to reset it. Once you do that, you’ll no longer have to complain about the low flame on Char Broil grill anymore. Before getting into the reset procedure, I have some advice for you.

How to Reset Char Broil Grill Flame Too Low?

Make sure you start the grill correctly. When firing up your grill, make sure you open the LPG gas supply first. Then, turn on the grill knobs. That way, the gas regulator won’t be tripped, and you won’t be facing this issue. With that said, here’s how you can reset the grill:

• Open the grill lid first (before doing anything else).
• Make sure all burner knobs are turned off.
• Turn off the propane tank (close the valve).
• Disconnect the regulator from the tank and wait for a minute.
• Reconnect the regulator, then slowly open the propane tank valve all the way.

So, as you can see, even the fix here is to follow the right startup procedure. Hopefully, it works for you and the issue is fixed. 

However, the gas regulator can also go bad or malfunction in some cases. If you suspect that could be the problem, just replace it with a new one. Then, you can move on to the other issues. But nine times out of ten, the issue is with the gas regulator.

How to Replace the Gas Regulator in a Char Broil Grill?

Before getting started, make sure that your grill is turned off. Work in a well-ventilated area and steer clear of any open flame or sparks. Here are the tools you’ll need to complement the replacement job:

• Adjustable wrench or crescent wrench
• Replacement gas regulator (available on Amazon or hardware stores)
• Optional: Teflon tape (for extra gas seal)
• A full propane tank

Now, let’s look at how you can replace the gas regulator and solve the Char Broil grill flame too low issue:

Step 01 – Remove The Old Regulator

Twist the propane tank valve clockwise until it’s completely shut off. Use your wrench to loosen and remove the old regulator hose from the propane tank. If it’s tight, hold the tank steady and carefully turn until it comes loose.

If the regulator is also connected to the grill via a fitting, use the wrench to unscrew that end as well. Some people hurt their fingers when doing this step. So, please be careful when you do this.

Step 02 – Attach the New Regulator

Make sure that the new regulator matches the old one in size and shape. The threads and fittings should also be the same. If the new regulator comes with a rubber gasket, that’s a plus.

Wrap Teflon tape around the threaded part of the new regulator where it connects to the grill. So, you’ll do it at the end of the grill and not at the end of the propane tank.

Even though Teflon tape is not required, it makes the connection a little stronger. It can’t hurt to do this and requires minimal effort. That’s why I always suggest that people do this.

Then, screw the new regulator hose onto the grill side and tighten it with your wrench. Keep tightening until it’s snug. Attach the other end to the propane tank. You’d have to keep turning it clockwise.

You can stop when the connection is firmly secured. Make sure you don’t keep anything too loose or overtighten things. It should be just right. Snug is what you’re looking for.

Step 03 – Check For Leaks

Now, it’s time to confirm whether you did a great job with the installation. Start opening the propane valve slowly. Listen closely for a hissing sound. If you don’t hear anything, that’s good. But if you hear something like that, there could be a gas leak.

Now, you just need to put some water in the connections. If you see bubbles forming, there’s 100% a gas leak. In that case, you need to make the connections tighter so that the gas is sealed.

Once you have taken care of the leak, light up the grill as you normally would. Follow the right procedure—the gas tank is turned on first, and then the grill. If the gas regulator was the issue, now your grill should be working properly.

However, if you’re still facing any Char Broil grill flame problems, there could be something wrong with other Char Broil grill parts. In that case, you’d have to keep on diagnosing. But nine times out of ten, it’s the gas regulator that’s at fault. But if not in your case, then keep on reading.

2. Flame Too High

The Char Broil grill flame being too high is also a common problem that a lot of people face. And there are many potential reasons behind it. So, let’s go through them one by one so that you can fully understand the situation.

Firstly, it could be due to turning on the control knob too quickly. It’s a pretty sensitive component. So, it’s important to turn it slowly to avoid this issue so that you don’t give the burner a lot of gas at once.

Secondly, the burner may be clogged and cause this issue. When the burner is dirty, it messes up the ratio of gas and airflow. That’s when the flame can become too high.

Thirdly, the air intake could be blocked. There could be rust, cobwebs, or dead insects in there that are getting in the way of proper airflow supply. Propane needs the right amount of air to burn. When it doesn’t get that, you’ll see a crazy high flame.

Solution:

First of all, you need to know how to adjust the flame on a Char Broil gas grill to avoid this issue. It’s not hard, but you must do it correctly so that the grill gets enough gas and works properly.

Start by trying to adjust the knob correctly. You need to turn it slowly but firmly. If you don’t press them hard enough when turning, it won’t feed the required gas to the burner. So, start with that.

Then, you have to clean the main burner if it’s dirty. You can use compressed air or a thin wire to get the dirt out of it. You can find more details on how to clean the burner in the section dedicated to it.

Similarly, you can also clean out the air intake. You can also adjust the air shutter to make sure that the grill gets enough gas. If the grill gets more oxygen, it should start working better. 

3. Yellow Flames Instead of Blue

Another flame problem behind your Char Broil grill burner not working properly is getting yellow flames. Normally, the color of the flames should be blue. But when it’s yellow, it’s not a good sign. Now, many reasons could cause this.

The most obvious one is when the main burner is dirty or the grill is dirty. If there’s a lot of buildup of dirt and gunk, the burner will burn the dirt. So, there’ll be a severe build-up of carbon dioxide, and that’s when you know this is the issue.

You’ll normally get a bad smell as well when the grill just burns through dust. Just check how the burner area looks. More often than not, it’s easy to tell if dirt is causing the issue by getting a good look at it.

Secondly, low gas pressure could also cause it. It can also be caused when something is wrong with the gas regulator. Thirdly, there could be a gas leak. In these situations, the ratio of fuel to airflow is messed up, and that’s what makes the yellow flame come out.

Solution:

If the burner area is dirty, you just need to clean it. There’s nothing more to it—just take out the components and get rid of as much dirt as you can. Vacuum the grill as well. If dirt was the issue and you remove a good amount of dirt, there’s a chance that this problem will go away for you.

If that doesn’t help you and the issue is due to low gas pressure, you have to reset the gas regulator. You already know how to do it. Follow the same process, and you’ll be good.

Thirdly, if there’s a gas leak, you can check it by applying some soapy water to the connections. If you see bubbles forming, this is the issue. In that case, tighten the connections, and you’ll fix the leak. I hope you’ll no longer see any yellow flames once you go through all these steps.

4. Faulty Main Burner

Another common reason behind the Char Broil grill flame being too low is a clogged or faulty main burner. Sometimes, it becomes pretty obvious when you look at the burner. When it’s dirty, it’s not a big issue.

But when the burner fails completely, that’s when you have to spend the big bucks. It’s not an ideal situation, but it’s something that does happen frequently. Especially if your unit is old and has been running for some time.

Solution:

When the burner is dirty, the solution is simple—you just need to make it clean. So, how to unclog grill burners? You can use an old toothbrush or a grill brush along with a vinegar and soapy water solution to clean it.

Remember that those stains won’t go away easily, and to make the burner truly unclogged, you need to put a lot of effort into it. You’d have to start by taking out the burners first.

Make sure the gas supply and all the connections to the grill are turned off. Once you unscrew them, use the solution you made to clean them. The small holes along the sides of the burner tubes can get clogged with grease or rust. Use a paperclip or pin to gently poke into each hole to clear blockages.

Tap the burner gently upside down to knock out debris. Blow through the burner tube (or use compressed air) to push out any dirt or bugs inside. You can also use a pipe cleaner if needed.

After you’re done cleaning it, I recommend one extra step that works like a charm. Soak the burners in warm soapy water or a vinegar-water solution for 15–30 minutes. Then, let it dry completely and put it back together.

Then, fire up the grill following the right lighting instructions and see if it works properly. If clogged burners were the issue, the problem should be solved now.

But if you still face the same issue, and the burners are still not working properly, you may have a faulty burner in your hand. In that case, your only option is to replace it.

How to Replace Char Broil Grill Burner?

Here’s the good news: changing the burner is simpler than you think. Whether your grill has two, three, or four burners, the process is pretty much the same. Here’s how you can do it:

Step 1—Remove the Old Burners

Start by turning off your grill and removing the grates on top. Underneath the grates, you’ll see metal covers. They’re normally called flame tents or burner shields. Lift those up and slide them out.

Once exposed, check your burners. If they’re rusty or falling apart, they likely need replacing. Each burner is usually held in place by two small metal clips called cotter pins. Use needle-nose pliers to gently pull them out.

Some burners may also have a tab that locks them in place. In that case, you have to twist it gently. There’s usually one burner that is connected directly to the igniter. You’ll need to disconnect it before pulling the burner out. Most burners should lift right out of the grill with little effort.

Step 2 – Fit The New Burners

Before installing the new burners, you need to make sure that they’re of the right size. Compare your new burners with the old ones. Check both the length and the diameter of the new burners.

If you’re using a universal replacement, be careful when checking. Sometimes universal burners are slightly fatter or longer. It’s not the end of the world if they don’t match. In that case, you’d just have to make some adjustments. But it’s always better if you can find exact matches.

If the new burners don’t fit perfectly, you can carefully bend the metal tab near the burner slot or even drill a small hole to make room. Just make sure they sit securely and align with the gas flow area.

Step 3 – Reinstall and Test the Grill

Once the new burners are in place, reinsert the cotter pins to secure them. Put the burner shields or tents back on top. If the new burners don’t have a little nub to hold these shields, you may need to lay them flat. They’ll still work. 

They just might move around a bit. Reconnect the gas and fire up your grill. You should now see a stronger, more even flame. If everything looks good, you’re done! However, if not, continue to diagnose.

FAQs

Conclusion

Now, you know the reasons behind Char Broil grill flame problems and how you can go about solving them. I’ve explained all the issues in detail and the way you can solve each of them. Don’t panic—stay true to the diagnostic process, and you’ll be fine.

There is a high chance that you can fix the issue by resetting the gas regulator anyway. But if that doesn’t work, clean the grill and then check the main burner. If you have issues with your Char Broil igniter, I also have a guide on fixing it. Check it out!