Fix My Grill Parts finder · repair notes

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How to measure a gas grill burner tube

Length tip-to-tip, diameter, inlet style, and rear tab — the four measurements that keep universal kits from flashing back.

easy PT20M Updated 2026-09-04

Clean versus clogged burner ports Left tube shows even open ports and a blue flame sketch. Right tube shows grease-clogged ports and a yellow uneven flame. BURNER TUBE · PORTS CLEAN Even blue cones. Every port open. CLOGGED Grease in the holes. Yellow, lift, dead spots. Ream with a bit smaller than the port. Do not drill oversized. Brass brush the row. Keep liquid out of the venturi / inlet. If the tube wall is lace under the ports, replace the set — do not patch holes.
Fig. — Burner tube: clean ports (left) versus clogged ports (right).
Rating-plate locations on a cart and a pellet grill Gas cart: plate on the left cart frame, inside the door, or firebox rear. Pellet: hopper back or firepot lip. GAS CART Plate: left cart / inside door / firebox rear PELLET Plate: hopper back / inside hopper / firepot lip Orange mark = sticker or riveted tag. Not the lid badge.
Fig. — Rating plate (orange). Cart: door / frame / rear. Pellet: hopper or firepot.

Retailer photos lie. Your tape does not. Use this before any “fits 4-burner” purchase. Model examples: Spirit tubes, Nexgrill 0830H, Char-Broil Performance.

Procedure

  1. Grill cold. Tank off. Remove grate and heat tent over one tube.
  2. Photograph the tube in place (inlet on orifice, rear tab/pin).
  3. Remove the tube. Measure overall length tip of inlet to tip of rear (or to the bend if curved).
  4. Measure outside diameter of the pipe (1” vs 5/8” matters).
  5. Note inlet style: open funnel, screened GS4, dual-tube casting, IR emitter feed.
  6. Note rear mount: forked tab, round pin, bolt flange.
  7. Count mains and carryover/crossover length separately.
  8. Search with brand + model + your length + diameter. Dry-fit before the first cook. Plate help: find model number / Weber data plate.

FAQ

Is the crossover included in length?

Measure mains and crossover apart. A 210 crossover on a 310 leaves a dead burner.

Calipers required?

A good tape gets you within 1/8”. Calipers help on diameter.

Related notes

Replace Char-Broil burner tubes

Pull stamped Char-Broil tubes, match length and inlet, reseat on the orifices, and leak-check. Universal tubes that are short are how flashbacks start.

Replace Char-Broil heat plates

Measure tent length and width on Performance and Commercial carts. Heat plates are the drip shields — when they lace, burners die. Do not buy by lid name alone.

Char-Broil igniter replacement

Box-store Char-Broil Performance and Commercial carts: piezo versus AA collector, electrode clips on stamped burners, and why the side burner is a separate lead.

How to find your grill model and serial number

Where rating plates live on Weber, Char-Broil, Nexgrill, and Traeger, what to photograph, and how to use the number in the parts finder without guessing from the lid badge.