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Next time you use the grill turn the gas on slowly. For some unknown reason when turned on quickly the regulator reduces the gas flow.
Another problem with some gas fittings is an auto shutoff if detects the slightest leak. Sometimes the shutoff is not 100% and allows a small amount of gas causing the weak flame.
You can try replacing the regulator to cure the gas flow problem, I believe the ignition is a piezo, if it does not click when you push it or turn it, it most likely needs to be replaced. If it still clicks, then there could be a bad wire or electrode.
try opening the tank really slowly and see if this helps. there is an overfill protection devise in the tank and if it is opened too quickly it will restrict the gas flow to the burners. hope this helps.
Check the excess flow safety device, which is part if the barbeque to cylinder connection, may have activated. To reset the excess flow safety device turn all burner control knobs and the cylinder valve off. Disconnect the regulator from the cylinder. Turn burner control knobs to high. Wait at least 1 minute . Turn burner control knobs OFF. Reconnect the regulator to the cylinder. turn cylinder valve slowly.
Agree with rjmbridge. I called the Weber support people and was told that there is a built in safety feature on the regulator that will cause the flame to burn at a low setting if the gas within the extension tube to the large tank and regulator is not allowed enough time to equalize. They suggested turning on the gas from the tank very slowly, allow about 2 minutes with the temperature control knob turned off, then turn the temp knob on and light. This worked for me.
The only way you can fix the low flame, low heat problem, is to remove the grill, take a medium sized paper-clip (staightened out) and clean out each individual hole on the steel burner, flame tube. (I'm sure there's a technical name for it).
Since they (the holes on the flame tube) face up unprotected, directly under the grill cooking surface they tend to get blocked quickly with continous use and certain foods, like pork ribs. Bad design unless all you plan on grilling is hot dogs.
There are about 500 individual holes, so plan on being there a while. Or in other words, do it close to the cooler.
I've been tempted to toss the thing into the woods a bunch of times over the past 2 years I've owned the dumb thing.
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