Yoder YS640 Review 2025: The Truth After 6 Months of Smoking & Grilling

June 20, 2025

Check out what six months with the Yoder YS640 has taught me! I gotta be honest - when I first came across this beast, I thought "Is it really gonna be the show-stopper smoker that everyone is shouting about?" But you know what? After countless briskets, ribs, and even those random Tuesday night dinners, I'm absolutely sold on this thing. This smoker has completely changed my outdoor cooking game, and frankly, I can't imagine going back to my old setup.

Now, if you're like me and you've been digging through endless online reviews aout the Yoder YS640 trying to find someone who'll give you the straight truth, you've come to the right place.

The difference between this Yoder and those other grills is absolutely night and day. I've put this smoker through weekend BBQ competitions and ordinary weeknight dinners, and it consistently delivers results that make my neighbours think I suddenly became some kind of pitmaster guru overnight.

Here I'm sharing what I've learned after actually living with this grill through multiple seasons, temperature swings, and every cooking challenge you can imagine. The honeymoon phase? Long gone. And you know what's crazy? I'm even more impressed with this beast now than when I first fired it up. If you're sitting on the fence about making this investment, stick around - I'll tell you exactly what you need to know before you pull that trigger.

About Yoder and the 640S Pellet Grill

Look, the Yoder name carries serious weight in the BBQ world, and once you dig into their story, you'll understand why. When I was researching my purchase, I discovered something that blew me away - unlike others brands that ship their manufacturing overseas, Yoder Smokers are made in Kansas, USA. This isn't some marketing gimmick either. The moment you lay eyes on this beast in person, their commitment to quality craftsmanship smacks you right in the face.

About the Brand

What sets Yoder Smokers apart from the competition? These folks aren't some run-of-the-mill company jumping on the pellet grill bandwagon. They're serious metalworkers who actually understand what pitmasters need. By the way, they back their products with warranties that'll make you smile: 10 years on the cooking chamber, 3 years on the ACS controller, and 3 years on the ceramic igniter. Having owned cheaper grills that barely survived two seasons, I absolutely love a company that stands behind their work like this.

Overview of the Yoder 640S

Now, at $4,295 CAD, the YS640S is definitely a serious investment compared to those entry-level pellet grills. But here's the thing - you're getting two cooking systems rolled into one incredible machine. Most pellet smokers can't handle high-heat grilling worth a damn, but the 640S? It achieves true flame grilling thanks to that Variable Displacement Damper system. You can smoke low and slow at 250°F for the perfect brisket, then crank this puppy up to 700°F for steaks with those beautiful sear marks you're after.

The control system is something else too - Yoder's ACS (Adaptive Control System) gives you WiFi and Bluetooth connectivity, so I can monitor and adjust temperatures through their mobile app while I'm inside watching the game. Plus, those two integrated food probes eliminate the need for separate thermometers. Pretty sweet setup, if you ask me.

Key Specs and Build Quality

Here's where the specs tell the real story:

Cooking Surface: 1,070 square inches total (four 8"×19.75" cooking grates plus 15.5"×28" second-level slide-out shelf)
Construction: 1/8-inch thick steel cooking chamber weighing a substantial 335 pounds
Temperature Range: 150-600°F for versatile cooking applications
Dimensions: 55" H × 61.3" L × 36.1" D (including shelves)
Hopper Capacity: 20 pounds of pellets

The build quality? Nothing short of incredible.

Opening that heavy lid with its counterweight system feels like you're operating a bank vault instead of your typical backyard grill. Those orange heavy-duty casters might seem like a small detail, but trust me - they make moving this 335-pound monster actually manageable. The 640S is old-school craftsmanship at its finest, something you just don't see in modern outdoor cooking equipment anymore.

Who Is the Yoder 640S Pellet Grill For?

After cooking everything from competition briskets to Tuesday night burgers on this beast for six months, I can tell you exactly who should drop $2,699 on a pellet grill. The Yoder YS640S isn't for everybody - and honestly, it shouldn't be.

Watch the full review and hands-on breakdown here:

Check out the full range of Yoder Smokers product here

Ideal User

This grill is perfect for serious home cooks who absolutely refuse to mess around with cheap equipment. If you've been burned by grills that can't hold temperature or rusted out after two seasons, you'll love this tank-like construction. I'm talking about folks who entertain regularly - that massive 1,070 square inches of cooking space handles multiple racks of ribs or several whole chickens without breaking a sweat. Just last weekend, I cooked for 12 people and still had room to spare.

By the way, this isn't just about cooking capacity. It's about cooking for people who actually care about the results. You know the type - they taste your BBQ and immediately ask "how'd you get it so tender?" or "what's your secret?" These are the folks who appreciate the difference between good and great.

Skill Level Required

Here's something that might surprise you - you don't need to be some pitmaster guru to get amazing results from this thing. The ACS Control System with WiFi connectivity makes it pretty forgiving for beginners. I was pulling off restaurant-quality cooks within my first few tries, if you know what I'm saying.

That said, you gotta be willing to learn the ropes, especially with that Variable Displacement Damper for direct flame grilling. It's not complicated, but you'll want to spend some time figuring out how those temperature zones work. Once you get the hang of it though, you're golden.

Best Use Cases

This is where the YS640S absolutely shines - it's not a one-trick pony like most grills out there. I've smoked the most tender briskets and pulled pork of my life on this thing. The temperature stability is incredible - holds steady for 12+ hour cooks without any babysitting.

But here's the kicker - crank it up to 700°F and you can sear steaks that rival any steakhouse. That two-piece heat diffuser lets you switch from smoking to direct flame grilling in seconds. No awkward modifications, no extra accessories to buy. For serious BBQ folks who want to excel at everything from low-and-slow to high-heat grilling, this grill delivers every single time.

What Makes the Yoder 640S Different?

I've tested my fair share of pellet grills over the years, and I can tell you straight up - the Yoder YS640S is in a completely different league. After months of pushing this beast through every cooking scenario I could think of, the differences between this machine and everything else became crystal clear.

Standout Features

The Variable Displacement Damper is hands down the game-changer that separates this grill from the pack. This thing lets me switch between indirect smoking and direct flame grilling without any of that awkward fumbling around with accessories or modifications. The two-piece heat diffuser with access door? Absolutely brilliant - I can create different heat zones across the cooking surface, something I always wished I had on those other pellet grills.

Now, the ACS (Adaptive Control System) - this is where things get really sweet. The WiFi and Bluetooth connectivity paired with two integrated food probes means I'm not constantly babysitting my cooks anymore. Having dealt with those finicky controllers on cheaper grills that would drive you absolutely crazy, this system is like a breath of fresh air.

Build vs. Competitors

Here's where most pellet grills fall flat - they use thin steel that can barely hold heat properly. The YS640S? We're talking 1/8-inch thick steel construction weighing a hefty 335 pounds. That's roughly twice the weight of those other grills that claim to be "comparable." When you open that counterweighted door, you immediately feel the difference - it's like the difference between a bank vault and a tin can.

You want to know what really impressed me? After six months of heavy use, my Yoder shows zero signs of wear. My previous grills? They'd start showing rust and deterioration after a year or two. This comes down to material quality - from those chrome-plated steel shelves to the heavy-duty orange casters that actually support this massive weight without wobbling around.

Performance and Versatility

The real magic happens with that temperature range. Perfect low-and-slow smoking at 250°F? Check. Searing temperatures up to 700°F for steaks? Absolutely. Throughout all my testing, this grill maintained rock-solid temperatures even when it's windy as heck outside.

That spacious 1,070 square inches of cooking area with nearly 12 inches of headroom handles everything from massive briskets to beer can chickens without breaking a sweat. The second-level slide-out shelf comes in handy when I'm juggling different items at the same time.

For serious grillers who appreciate quality craftsmanship, the YS640S delivers performance that justifies every penny of that premium price tag. It's simply built different - and once you cook on one, you'll know exactly what I mean.

What Customers Are Saying About the Yoder 640S

I've been digging through forums and talking with fellow Yoder owners for months now, and let me tell you - the feedback on this YS640S is something else. Most pitmasters I've connected with aren't just happy with this grill, they're absolutely raving about it. This isn't just another pellet grill to these folks - it's a genuine game-changer in their outdoor cooking setup.

Overall Sentiment

Here's the thing - customers keep saying the same thing over and over: this Yoder delivers professional-grade results that actually justify dropping $4,000. From BBQ competition teams to weekend warriors, everybody reports that this grill's performance blows their expectations out of the water. What really gets people excited is that unlike those other pellet grills that promise versatility but can't deliver, the Yoder actually does what it says it's gonna do. By the way, tons of users mention they were nervous about that price tag at first, but after the first few cooks? Those concerns just vanished.

Most Common Praise

The build quality gets the loudest cheers from the Yoder community, and I mean loud! People constantly talk about that 1/8-inch thick steel cooking chamber that holds rock-solid temperatures even when it's windy as heck outside. But here's what really gets them going - the true versatility. You can smoke low and slow at 250°F for perfect briskets, then crank this beast up to 700°F for steaks that'll make you think you're at a high-end steakhouse. The Variable Displacement Damper? Absolute customer favorite. People keep telling me it's the one feature that separates this grill from everything else they've ever owned.

Notable Critiques

Of course, nothing's perfect, and the YS640S has its challenges. That 335-pound weight makes setup a real workout - though those heavy-duty orange casters help once you get it where you want it. Some first-time users mention there's a bit of a learning curve with the direct flame grilling function, which makes sense if you know what I'm saying. The WiFi connectivity works great, but a few owners say it took some patience to get configured properly. The biggest complaint? The price, naturally. But here's the funny thing - almost everyone follows that up with "but it's absolutely worth every penny." The other thing customers keep mentioning is once you've cooked on a Yoder, going back to cheaper grills becomes virtually impossible.

What We Love About the Yoder 640S

Six months with this Yoder YS640S has turned me into something of a neighborhood legend, if you know what I'm saying. My buddies now show up unannounced on weekends just hoping I've got this beast fired up. This isn't just another pellet grill - it's become the centerpiece of every gathering, and honestly, it keeps surprising me with what it can do.

Personal Experience

I'm still finding new things to love about this unit, by the way. That first weekend when I threw a brisket on there, the temperature stability blew my mind - held rock steady at 250°F for 12 straight hours without me babysitting it once. Of course, switching from smoking to direct flame grilling with that Variable Displacement Damper takes maybe 10 seconds. I've actually gotten rid of three other grills since getting the Yoder - they just can't compete, you know?

The 1,070 square inches of cooking real estate handles whatever I throw at it. Last month I loaded up four pork butts, two whole chickens, and a full rack of ribs for the neighborhood cookout. Everything fit like a glove, and I could still get to everything thanks to that slide-out shelf on the second level.

Best Cooking Moments

The absolute crown jewel moment was a 16-hour brisket that honestly rivaled the best Texas joint I've ever been to. That ceramic ignition fires up every single time - even during those brutal cold mornings we had this spring, something like that. Rain or shine, this machine delivers consistent results that make me look like I actually know what I'm doing.

But here's the real game-changer - when I figured out how that two-piece heat diffuser creates different temperature zones across the cooking surface. Now I can smoke chicken thighs at 275°F while getting the skin crispy over direct flame at the same time. You can't do that on those other pellet grills, trust me.

Favorite Features

The build quality is what gets me most excited. At 335 pounds with that 1/8-inch steel construction, this isn't some weekend warrior toy - it's built like a tank and it'll probably outlast my truck.

The ACS Control System with Wi-Fi has completely changed how I approach long cooks, by the way. I can monitor everything from my phone while I'm inside watching the game. Those chrome-plated steel shelves give me actual workspace instead of the flimsy plastic junk on my old grills.

And those heavy-duty orange casters might look like a small detail, but they make moving this 335-pound monster around my deck actually possible. Once you cook on a Yoder, there's absolutely no going back to anything else. I wouldn't have anything else in my backyard.

Best Features of the Yoder 640S

Look, when folks ask me what makes this Yoder YS640S worth every penny of that $4,295 investment, I've got three absolute game-changers that separate this beast from every other pellet grill I've ever owned. These aren't just fancy marketing features - they're the real deal that'll change how you cook outdoors forever.

Feature 1: Variable Displacement Damper

This Variable Displacement Damper is hands down the most brilliant thing I've seen on a pellet grill. You know what most pellet grills can't do? They can't give you real flame grilling - they just blow hot air around and call it searing. Not this beast!

With the Yoder, I can smoke a brisket low and slow at 250°F with perfect indirect heat, then slide that damper open and BAM - I've got direct flame access hitting 700°F for steaks that'll make your steakhouse jealous. The two-piece heat diffuser with that access door? Pure genius. You can create different temperature zones across the entire cooking surface - something I wish I had on every grill I've ever owned.

Feature 2: Wi-Fi Smart Control

The ACS Control System - that's their Adaptive Control System, by the way - has completely changed my long smoking game. I'm talking WiFi and Bluetooth connectivity that actually works! I can monitor and adjust temperatures through their app while I'm inside watching the game, no more babysitting the grill all day long.

Those two integrated food probes? They send real-time temperature data straight to my phone. I've done overnight cooks where this thing held steady within 5 degrees for 12+ hours straight, even when it was windy as heck outside. If you're new to smoking, this technology makes you look like a pro from day one. If you're already experienced, you'll love the precision this system gives you.

Feature 3: Heavy-Duty Steel Construction

Nothing - and I mean nothing - comes close to this build quality. We're talking 1/8-inch thick steel construction weighing 335 pounds. This isn't some flimsy backyard toy that'll rust out in two seasons - it's built like an absolute tank.

Those heavy-duty orange casters might look like a small detail, but trust me, they make moving this monster around manageable. The door counterweight system? It feels like opening a bank vault every single time. This kind of construction means superior heat retention and rock-solid temperature stability that those thin-walled grills can't even dream of matching. Six months of heavy use and there's zero wear, zero warping - this thing's built to outlast everything else in your backyard.

Final Word: Is the Yoder 640S Worth It?

Look, after six solid months with this Yoder YS640S, I can't be any clearer - this beast has absolutely changed everything about how I cook outdoors. This grill delivers value that goes way beyond the sticker shock. You absolutely get what you pay for with this thing.

Here's what really gets me - the build quality just embarrasses everything else I've owned. While those cheap pellet grills feel like they're gonna fall apart if you look at them wrong, this American-made tank is gonna outlast my truck, probably my house too! And the fact that it handles both low-and-slow smoking and high-heat searing means I literally threw out two other cooking devices. This two-in-one setup alone pays for a huge chunk of that investment.

This Yoder is the last grill I'm ever gonna need to buy. Period.

The learning curve with that Variable Displacement Damper took me a few weekends to master, I'll be honest. But once you figure out how to work those temperature zones? Game over. I'm pulling restaurant-quality food off this thing that has my buddies begging for invitations to Sunday dinner.

Just last weekend, while I was pulling a perfect pork shoulder off the grates, it hit me - this isn't just some cooking appliance sitting on my deck. This Yoder has become the centerpiece of every family gathering, every neighborhood cookout, every personal victory in my BBQ journey.

Once you cook on a Yoder, you're not going back to anything else. Trust me on this one - absolutely worth every single penny.

FAQs

Let me tackle the questions I get asked most when folks see this beast in action at my place. After six months of living with the YS640S, these are the things everybody wants to know.

1: What are the differences between the YS480 and the YS640?

There are two differences between the YS480 and the YS640. The first is size. The cooking surfaces are 33% larger on the YS640. The second difference is the addition of the Variable Displacement Damper (VDD) in the YS640.

2: What is the cooking area on the YS480 and the YS640?

The cooking area on the YS480 are 20″ x 24″ on the main grates and 15 ½” x 20″ on the optional 2nd shelf. The cooking area on the YS640 are 20″ x 32″ on the main grates and 15 ½” x 28″ on the optional 2nd shelf.

3: Head Room?

11 ¾” with the 2nd shelf removed.

4: What gauge of steel is used?

The cooking body is constructed from 10-gauge steel, which provides heat retention suitable for 4-season cooking. The hopper assembly and cart are constructed from 14-gauge steel.

5: What are the overall dimensions of the cookers?

The YS480 is 53″ long (including the side shelf), 54″ tall and 35″ deep. The YS640 is 61″ long (including the side shelf), 54″ tall and 35″ deep.

6: What are the cooking grates made of?

The main cooking grates are constructed of ¼” steel bar and then finished with a hard chrome surface.

7: What is the 2nd shelf cooking grate made of?

#9 expanded metal contained in a ½” square tube frame.

8: Are the front and side shelves standard?

Yes.

9: What are the front and side shelves made from?

The front and side shelves are constructed from 7/16″ round bar and then finished with a hard chrome surface. **Solid Stainless Steel shelves are optional on the standard cart and standard on the Competition cart.

10: What are the dimensions of the front and side shelves?

YS480: front shelf is 12 ½” deep x 23″ wide; side shelf is 19″ deep x 15″ wide. YS640: front shelf is 12 ½” deep x 31″ wide; side shelf is 19″ deep x 15″ wide.

11: Is there enough clearance to open the door with a full size restaurant pan sitting on the front shelf?

Yes, there is over 4″ of clearance between the bottom of the door and the front shelf.

12: How do you move the cooker around?

The standard cookers are fitted with a set of wheels and casters so it moves easily across hard surfaces. The shelf on the Right Hand side doubles as a handle for moving the grill across turf or uneven surfaces. The Competition Cart model has 4 – 8″ flat-free tires for handling changing terrains. **Optional 10″ flat-free tires are available for Competition Cart models.

13: What is the hopper capacity?

The hopper holds 20-pounds of pellets.

14: What’s the temperature range?

The temperature range for the 480 or 640 pellet grill is from 150-degrees to 600-degrees.

The temperature range for the 1500 pellet grill is from 175-degrees to 500-degrees.

15: How do you control temperature?

The temperature is digitally controlled in 5-degree increments.

16: How long will it run on a hopper full of pellets?

The cookers will run up to 12-hours depending on the cooking and ambient temperatures.

17: How many pellets are used in a long slow smoke?

Pellet consumption ranges from 1½-pounds to 4-pounds per hour depending on the cooking temperature and environment.

18: How long does it take to heat up?

The heat up period for direct grilling is 10 to 15-minutes. The heat up period for indirect cooking is 20 to 30-minutes.

19: Where is the firebox located?

The firebox is located on the Left Hand side of the pit.

20: Why did you locate the firebox on the Left Hand side?

Airflow is less volatile from left to right (firebox to chimney) than a center mounted firepot, so the Left Hand placement significantly reduces the hot spots in the corners and in the front and back edges of the cooker which allows the cook to utilize more of the cooking area.

21: What makes the Yoder such a Versatile Cooking System?

The Yoder Pellet Grills offer two unique setups depending on the style of cooking that you want to do. The first is the traditional pellet grill setup, which has the heat diffuser in place; this is the ideal setup for smoking and baking. In this setup the air and smoke travel through the length of the cooking chamber, similar to an offset wood pit, imparting excellent color, flavor and texture into the food. The second is with the heat diffuser removed allowing you to sear or roast directly over the firepot. ** 2-piece diffuser adds access to the firepot without removing the diffuser.

22: How does the Variable Displacement Damper (VDD) work?

When the YS640 is setup traditionally (heat diffuser in place) the Variable Displacement Damper allows the pit-master some additional grate level temperature control. With the damper pushed all of the way in the left half of the grill will run hotter, when positioned all the way out (open) the right end of the grill will run hotter. With the damper pushed in about 5-inches the grate surface will cook fairly even, which creates the ideal environment for slow cooking similar cuts of meat. With the direct grill kit in place it is recommended to open the damper all the way to allow the heat to develop across the entire cooking surface.

23: How does the direct grill option work?

There are two ways to utilize the direct grill option, first is to remove the original grate or both grates and install the GrillGrates over the diffuser. This creates an ideal grilling environment for wings, chicken Spedini, chicken breast and other meats that benefit from slightly less direct heat. The full direct method is created by removing the heat diffuser and then replacing the standard cooking grate or grates with the direct grill kit which is perfect for cooking burgers, steaks, thick chops and similar cuts of meat.

24: What temperature will the direct grill surface achieve?

With the GrillGrates kit in place and the diffuser out the grate temperature can quickly climb past 700-degrees depending on the set point.

25: Can I sear a steak on a Yoder Pellet grill?

With the direct grate system in place you can sear a steak and achieve the cooking time, color, texture and grill marks previously associated with cooking over gas or charcoal.

26: What’s the warranty?

Warranty is an industry leading 10 years on the cooking body, 3 years on the control system, and 3 years on the ceramic igniter. View the warranty

27: How does it ship to me?

Standard cart YS480 and YS640 are shipped boxed. Assembly of the stand and attachment of the stand to the body is required. Please refer to the assembly manual for detailed instructions. All other models are shipped fully assembled banded to a pallet. All units are delivered to your driveway and unloaded utilizing a lift gate. Delivery is only available to your driveway if there is access for delivery trucks to enter and exit. There are cases that limited access require the product be shipped to a business or picked up at the local freight facility.

28: What is the best way to clean the inside of the pit?

Start by disassembling the pit, vacuum the body, use a thin blade putty knife to remove any buildup and finish by wiping down with a citrus based cleaner.

29: Where are Yoder Smokers built?

We design, test and build all of our pits in the USA.

Want to Learn More?

Explore the Yoder YS640S Competition Pellet Grill
View Product Page

Not Sure Which Yoder Smoker Is Right for You?
Read our comparison guide of all Yoder models

Back to blog