It starts the same way every time: you turn the knob, press the igniter, and wait for the comforting whoosh of flames. But nothing happens. Or worse, one burner lights while the others sputter and click. Grill issues often show up right before an important cookout—when you need it working the most. If your barbecue isn’t heating properly, won’t ignite, or has an uneven flame, it’s not just annoying. It could be unsafe. In this guide, we’ll walk through the most common grill repair problems we see across the San Francisco Bay Area and explain which fixes you can handle yourself—and which call for a pro. If you’re stuck with a stubborn grill, Fire & Metal offers on-site gas grill repair and cleaning services to get you back to cooking.
Most common grill problems (and how to fix them)
Whether you own a Weber, DCS, Lynx, or a custom built-in grill, most problems boil down to a few repeat issues.
1. The grill won’t ignite
This is by far the most common service request we get. It usually traces back to one of these:
- Dead or corroded ignition battery
- Loose electrode wiring
- Grease-clogged igniters
- Cracked ceramic electrode tip
- Gas supply issue (e.g. valve not open or regulator failure)
Quick Fix:
Check your ignition battery compartment first—many customers don’t even realize their grill uses one. If replacing the battery doesn’t help, it may be time to replace the ignition module or clean the electrode.
If your igniter clicks but doesn’t spark, or sparks without ignition, we can diagnose it during a grill maintenance and repair appointment.
2. Uneven flame or low heat
If only half the burners are working or flames are yellow and weak, your heat distribution is compromised.
Likely causes:
- Burner holes are clogged with grease or rust
- Regulator failure (especially after tank replacement)
- Venturi tubes blocked by insects or debris
- Heat shields/flavorizer bars are corroded
Quick Fix:
Turn off the gas and use a wire to clean burner holes. Check for obstructions in the burner and venturi tubes. If burners are cracked or heavily rusted, replacement is the safest route.
Fire & Metal’s grill burner repair services include disassembly, deep cleaning, and replacement of failing components.
3. Clicking but no flame
This usually means your igniter is working, but gas isn’t reaching the burner. It could be:
- Gas valve failure
- Clogged manifold
- Regulator stuck in safety bypass mode
- Loose or disconnected gas line
Pro Tip:
If you smell gas but there’s no ignition, shut everything down immediately. Gas buildup inside a closed grill box can ignite explosively once the spark catches. Don’t risk it—schedule a professional inspection.
4. One burner lights, the rest don’t
Often, this happens after a new propane tank is installed. It’s not always a part failure—it might be your regulator in safety lock mode.
Quick Fix:
- Shut off everything: grill knobs and tank
- Disconnect the regulator for 30 seconds
- Reconnect slowly and reopen the tank valve
- Try ignition again
If the issue persists, a replacement regulator or manifold cleaning might be needed.
When to repair vs replace grill components
Grills are modular machines—most parts can be replaced individually if caught early.
Here’s our honest guide:
| Component | Repairable? | When to Replace |
| Burners | Yes | If rusted through or warped |
| Igniters | Yes | If no spark after cleaning |
| Grates | Sometimes | If pitted or flaking coating |
| Flavorizer bars | Yes | If warped or rusted through |
| Regulator | Replace | If in bypass mode or leaking |
| Gas valves | Yes | If stuck, leaking, or corroded |
At Fire & Metal, we stock common replacement parts and can source brand-specific components for most major manufacturers. We’ll never recommend a full grill replacement unless your frame or firebox is compromised.
Grill repair vs cleaning: What’s the overlap?
A lot of issues we get called for as “repairs” turn out to be the result of deep grime and lack of maintenance.
For example:
- A clogged burner may just need steam cleaning, not replacement
- Weak flames are often due to blocked ports or spider webs in venturi tubes
- Foul smells come from old grease and mold in the drip tray—not broken parts
That’s why our grill cleaning services include a full diagnostic check. We don’t just shine it up—we test ignition, burners, heat flow, and part condition. If something needs fixing, we’ll handle it on the spot.
How much does grill repair cost?
Here’s a transparent breakdown based on hundreds of Bay Area service calls:
| Service | Average Cost |
| Igniter replacement | $65–$120 |
| Burner cleaning & tune-up | $85–$150 |
| Burner replacement | $80–$300 (depending on model) |
| Regulator replacement | $50–$100 |
| Full system inspection + cleaning | $249–$349 |
We price transparently and only recommend replacements when necessary. If your grill is a candidate for restoration, it’s almost always more cost-effective than replacement.
Can I repair my grill myself?
You can handle minor fixes yourself—replacing batteries, cleaning burners, swapping out flavorizer bars. But anything involving gas flow, pressure regulators, or manifold disassembly should be handled with caution.
If you’re not 100% confident, we recommend scheduling a grill repair technician. Grills are high-heat, gas-driven appliances. Mistakes can be dangerous.
What kinds of grills can Fire & Metal repair?
We work with:
- Gas grills (propane or natural gas)
- Built-in outdoor kitchen grills
- Standalone cart grills
- Hybrid gas/charcoal models
- Luxury brands like Lynx, Twin Eagles, FireMagic, DCS
- Retail brands like Weber, Napoleon, Bull, Blaze
Not sure if we can fix your model? Send us a photo and we’ll confirm within a few hours.
FAQs about grill repair
Why won’t my grill ignite?
It could be a dead battery, dirty igniter, gas blockage, or regulator issue. Our technicians will pinpoint the exact cause.
How do I fix an uneven flame?
Clean the burner holes and check the regulator. If parts are rusted or damaged, they may need replacing.
Is it safe to DIY gas grill repair?
Only for minor issues. Anything involving gas lines or valves should be handled by a certified tech.
Can I get parts replaced during cleaning?
Yes. We carry common components and can replace most parts during the same visit. Learn more here.
Final thoughts: Don’t wait until your grill fails mid-party
Grill problems don’t fix themselves. And a failed ignition or low flame might be the least of your worries—unattended issues can become fire risks, health hazards, or lead to total equipment failure.
If your grill isn’t lighting, isn’t heating evenly, or smells off, don’t guess. Let Fire & Metal’s expert team assess and fix it—on your patio, on your schedule.
Book your grill repair and tune-up now and we’ll make sure your next cookout runs smooth from the first spark.
