Pit Boss Troubleshooting

Pit Boss 850 Not Igniting: Causes and Fixes

Pit Boss start-up follows the same combustion chain as any pellet grill — fuel, heat, air — with two model-specific traps: the flame broiler plate must be positioned correctly for the firepot to breathe, and the grill must never be restarted on top of a firepot already full of unburned pellets.

Quick Answer

Common causes include unburned pellets already sitting in the firepot, an auger tube that emptied after the hopper ran out, ash blocking the firepot air holes, a worn igniter element, a blocked or failed combustion fan, damp pellets, and a tripped GFCI outlet. Check first that the firepot is clean and empty and that the grill is receiving power before replacing any part.

Which symptom matches yours?

  • The grill runs the start-up cycle but never produces smoke or flame
  • Pellets pile up unburned in the firepot
  • The display is dark or the grill has no power
  • It starts, smokes briefly, then goes out
  • The problem began after the hopper ran empty mid-cook
  • It only fails to light in cold or windy weather

Diagnostic decision tree

No display, no fan

→Power: outlet, GFCI, cord and fuse.

Fan and auger run, no pellets arrive

→Prime the auger or clear a hopper bridge.

Pellets arrive, nothing catches

→Igniter element or firepot airflow.

Lights then dies

→Overloaded firepot, ash blockage or damp pellets.

Flame broiler open during start-up

→Set it to the position the manual specifies for start-up so the firepot draws correctly.

Fixes, easiest first

1. Confirm power and start-up conditions

AddressesNon-mechanical start failures.

  1. Plug the grill directly into a known-good outlet and reset the GFCI if it has tripped.
  2. Check the controller fuse if the display is dark.
  3. Fill the hopper with fresh, dry pellets.
  4. Follow the start-up sequence and lid position specified in the owner's manual for your 850-series model.

Expected resultDisplay active, fan audible, auger cycling.

When to stopIf it lights normally, no further work is needed.

2. Empty and clean the firepot before every restart

AddressesA loaded firepot, which both prevents ignition and creates a flare risk.

  1. Unplug the grill and let it cool completely.
  2. Remove grates, grease tray and the flame broiler plate.
  3. Scoop out any unburned pellets, then vacuum the firepot to bare metal and clear each air hole.
  4. Vacuum ash from the barrel base and reinstall parts in the correct order.

Expected resultIgnition within the normal start-up window.

When to stopNever attempt another start with pellets already in the firepot.

Restarting over a heaped firepot can produce a sudden delayed flare when it finally catches. Always clear it first, and only vacuum cold ash.

3. Prime the auger

AddressesAn empty auger tube after the hopper ran out.

  1. Fill the hopper with dry pellets and stir to prevent bridging.
  2. Run the prime routine or start a cycle until pellets drop into the firepot.
  3. Remove those primed pellets, then run a normal start-up.

Expected resultPellets feeding steadily during start-up.

When to stopIf nothing feeds, treat it as an auger jam instead.

4. Test the igniter element

AddressesA worn or failed hot rod.

  1. With a clean, empty firepot, begin a start cycle and look for a glowing element.
  2. No glow or a dull glow indicates a failing igniter — a documented wear part on pellet grills.
  3. Confirm the igniter wiring connector is seated and free of corrosion before ordering parts.
  4. Fit the correct Pit Boss replacement igniter for your 850-series model.

Expected resultA clearly glowing element and pellets catching within the normal window.

When to stopA dead element is the answer; do not keep cycling the grill on top of it.

Never reach into the firepot during a start cycle.

5. Restore combustion airflow

AddressesA fan or air path that cannot support ignition.

  1. With the grill unplugged, check that the combustion fan spins freely and is clear of ash and grease.
  2. Clear the chimney and confirm the grease drain is not blocked.
  3. Reinstall the flame broiler plate correctly — a misaligned plate changes how the firepot draws air.
  4. Move the grill out of strong direct wind for start-up.

Expected resultAudible airflow and a clean light-off.

When to stopA fan that will not spin or that grinds needs replacement.

Pit Boss 850 / Navigator 850: what makes this model different

Ignition system
Electric igniter element in the firepot with a combustion fan
Model-specific detail
Sliding flame broiler plate sits directly over the firepot and must be positioned per the manual for correct draw
Controller
Digital board with start-up cycle, meat probe inputs and — on Navigator and current Pro Series boards — PID-style control
Power
120V; commonly run on a GFCI outdoor circuit that can trip in wet weather
Service parts
Igniter element, combustion fan, auger motor, temperature probe, control board

When to stop troubleshooting

  • Flame or smoke from the hopper — shut down immediately and do not restart the grill.
  • Any smell of burning insulation, a hot control housing, or a damaged power cord.
  • The firepot has repeatedly filled with unburned pellets — clear it fully rather than making another attempt.
  • Water has entered the hopper, control housing or outlet.
  • Clean firepot, dry pellets, confirmed power, glowing igniter and a working fan but no ignition — contact Pit Boss support with your model and serial number.

Sources and references

Procedures are summarised from the sources above and from the owner's manual for this model. Always follow the manual supplied with your grill where it differs.

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Common Questions

Frequently Asked Questions

Why won't a Pit Boss light after the hopper runs empty?
Running dry empties the auger tube as well as the hopper, so the first minutes of the next start-up deliver air instead of fuel. Refill, prime until pellets drop into the firepot, clear those pellets out, and start normally.
Can the flame broiler stop the grill igniting?
It can interfere. The plate sits directly above the firepot, so a misaligned or grease-jammed plate changes how the firepot draws air during light-off. Reinstall it in the position the owner's manual specifies for start-up.
Is a GFCI trip a common cause?
Yes on outdoor circuits, particularly after rain. A dark display with no fan noise is far more often a power problem than a controller failure — check the outlet and reset the GFCI before opening the grill.