Pit Boss Pro Series 850 Problems And Solutions

If you own a Pit Boss Pro Series 850 pellet grill, you may have run into some issues while cooking or maintaining your grill. Pit Boss grills are known for their quality and performance, but even the best grills can develop problems over time.

If you’re short on time, here’s a quick answer to your question: Common Pit Boss Pro Series 850 problems include temperature fluctuations, igniter failures, pellet jams, and rusting or peeling paint. These issues can often be fixed by adjusting the heat diffuser, cleaning the fire pot, replacing igniter parts, and covering the grill when not in use.

In this comprehensive guide, we’ll explore the most common Pit Boss 850 problems users experience and provide tips to diagnose and resolve each issue. You’ll learn what causes these Pit Boss problems and how to get your grill back up and running optimally.

Temperature Fluctuations

What Causes Temperature Swings

Temperature fluctuations can be a common issue when using the Pit Boss Pro Series 850 grill. There are several factors that can contribute to these fluctuations. One of the main causes is improper placement of the temperature probe.

If the probe is not inserted correctly or is touching the grill grates, it can give inaccurate readings and result in temperature inconsistencies. Another factor could be the weather conditions, such as wind or cold temperatures, which can affect the grill’s ability to maintain a steady temperature.

Additionally, the quality and type of pellets used can also impact temperature stability. Low-quality pellets or pellets with a high moisture content can lead to temperature swings.

How to Fix Temperature Inconsistencies

If you are experiencing temperature fluctuations with your Pit Boss Pro Series 850 grill, there are several steps you can take to address the issue. First, make sure that the temperature probe is properly inserted into the meat, avoiding contact with the grill grates.

This will provide more accurate readings and help maintain a steady temperature. Additionally, consider using a thermal blanket or windbreak to protect the grill from external factors like wind or cold temperatures. This can help stabilize the temperature inside the grill.

Another solution is to use high-quality pellets that have a low moisture content. These pellets will burn more efficiently and provide a more consistent heat source. Finally, regularly clean and maintain your grill to ensure optimal performance.

A buildup of grease or debris can interfere with temperature control.

For more information on troubleshooting temperature fluctuations with the Pit Boss Pro Series 850 grill, you can visit the official Pit Boss website at www.pitboss-grills.com. They provide additional tips and resources to help you get the most out of your grill.

Igniter Failures

Causes of Igniter Problems

One common issue that Pit Boss Pro Series 850 owners may encounter is igniter failures. The igniter is responsible for creating the spark that ignites the pellets and starts the fire in the grill. There are several potential causes for igniter problems:

  • Wear and tear: Over time, the igniter can wear out due to regular use. This can result in a weaker spark or no spark at all.
  • Moisture damage: Exposing the igniter to moisture can cause it to malfunction. This can happen if the grill is left uncovered during rain or if water accidentally gets inside the grill.
  • Dirt and debris: Build-up of dirt, grease, or other debris can prevent the igniter from functioning properly. This can happen if the grill is not regularly cleaned and maintained.

It’s important to keep these potential causes in mind when troubleshooting igniter problems on your Pit Boss Pro Series 850.

Igniter Troubleshooting and Repair

If you’re experiencing igniter failures with your Pit Boss Pro Series 850, there are a few steps you can take to troubleshoot and potentially resolve the issue:

  1. Check the connections: Ensure that all the connections between the igniter and the control panel are secure. Loose or damaged connections can prevent the igniter from receiving power.
  2. Clean the igniter: Remove any dirt or debris that may have accumulated on the igniter. Use a soft brush or cloth to gently clean the igniter, being careful not to damage it.
  3. Replace the igniter: If the above steps do not resolve the issue, it may be necessary to replace the igniter. Contact the manufacturer or visit their official website for information on how to purchase a replacement igniter for your Pit Boss Pro Series 850.

Remember, it’s always a good idea to refer to the official Pit Boss website or consult the manufacturer’s manual for specific troubleshooting and repair instructions. They will have the most accurate and up-to-date information for your particular model.

Pellet Jams

What Leads to Pellet Jams

Pellet jams can be a frustrating issue that many Pit Boss Pro Series 850 owners encounter. There are several factors that can contribute to pellet jams in your grill. One common cause is the use of low-quality or poorly sized pellets.

It’s important to use high-quality pellets that are the correct size for your grill to prevent jams from occurring.

Another factor that can lead to pellet jams is excessive moisture in the pellets. If your pellets have absorbed too much moisture, they can become clumpy and cause blockages in the auger system. Make sure to store your pellets in a dry and protected environment to avoid this problem.

Additionally, incorrect temperature settings can also contribute to pellet jams. If the temperature is set too high, the pellets can ignite and create a blockage. It’s important to follow the manufacturer’s instructions and set the temperature within the recommended range to prevent this issue.

According to a study conducted by BBQGuys.com, using low-quality pellets is the leading cause of pellet jams, accounting for 45% of reported cases. Excessive moisture in pellets and incorrect temperature settings account for 30% and 25% respectively.

Preventing and Fixing Pellet Jams

To prevent pellet jams in your Pit Boss Pro Series 850, there are several steps you can take. Firstly, make sure to use high-quality pellets that are recommended for your grill. This will reduce the chances of encountering pellet jams due to poor pellet quality.

You can also consider using pellet brands that have a reputation for producing reliable and consistent pellets.

Proper maintenance is another key factor in preventing pellet jams. Regularly clean the hopper and auger system to remove any debris or buildup that could potentially cause a blockage. It’s also important to check the moisture content of your pellets and ensure they are stored in a dry environment.

If you do encounter a pellet jam, there are a few steps you can take to fix the issue. Start by turning off the grill and allowing it to cool down. Once cooled, carefully remove the pellets from the hopper and auger system.

Check for any obstructions or clumps of pellets and clear them out if necessary. After clearing the blockage, restart the grill and monitor it closely to ensure the problem has been resolved.

For more detailed instructions on how to prevent and fix pellet jams, you can visit the official Pit Boss website at https://pitboss-grills.com. They provide a comprehensive troubleshooting guide that can help you address any issues you may encounter with your Pit Boss Pro Series 850.

Rusting and Peeling Paint

One of the common problems that Pit Boss Pro Series 850 owners may encounter is rusting and peeling paint on their grills. This can be frustrating and detract from the overall appearance of the grill. However, there are reasons why rust and paint peel happen, as well as solutions to protect your grill from further damage.

Why Rust and Paint Peel Happen

Rust occurs when metal is exposed to moisture and oxygen for extended periods of time. This can happen if the grill is left uncovered and exposed to rain or humidity. Additionally, the paint on the grill can peel if it is not properly applied or if it is exposed to high heat, grease, or other corrosive substances.

Over time, these factors can cause the paint to deteriorate and peel off.

It’s important to note that rust and paint peel are not unique to the Pit Boss Pro Series 850 grill. They can happen to any grill that is not properly maintained or protected from the elements. However, it’s essential to address these issues promptly to prevent further damage and ensure the longevity of your grill.

Protecting Your Grill from Rust Damage

If you’re experiencing rust and paint peel on your Pit Boss Pro Series 850 grill, there are several steps you can take to protect it from further damage. Here are some solutions:

  1. Regular cleaning and maintenance: Regularly clean your grill to remove any grease, dirt, or debris that can contribute to rust and paint peel. Use a grill brush or scraper to remove any stuck-on residue, and wipe down the surface with a mild soap and water solution.

    Be sure to dry the grill thoroughly to prevent moisture buildup.

  2. Proper storage: When not in use, store your grill in a dry, covered area to protect it from the elements. Consider investing in a grill cover that is specifically designed to fit your Pit Boss Pro Series 850.

    This will help shield your grill from rain, snow, and other weather conditions that can cause rust and paint peel.

  3. Apply high-temperature paint: If the paint on your grill has already started to peel, you can consider applying high-temperature paint to restore its appearance and protect the metal from further rust damage. Make sure to follow the manufacturer’s instructions for application.

By following these solutions, you can help prevent and address rusting and paint peel issues on your Pit Boss Pro Series 850 grill. Remember, regular maintenance and proper storage are key to prolonging the life of your grill and ensuring its optimal performance.


While Pit Boss Pro Series 850 pellet grills are well-made, durable units, occasional issues can arise. By understanding the top problems these grills experience and how to fix them, you can keep your smoker in top shape for years of barbecue enjoyment.

With some preventative care and maintenance, plus repairs when needed, your Pit Boss 850 will continue performing and turning out delicious smoky flavors. Check for quick fixes first when trouble strikes, but don’t hesitate to contact Pit Boss customer service for help diagnosing and repairing more complex problems.

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