How to Assemble Your Yoder Smokers YS480s or YS640s Pellet Grill

Jul 21, 2025 • Jerry Crespo

You’ve just made a serious upgrade to your outdoor cooking game. The Yoder Smokers YS480s and YS640s pellet grills are industry leaders—built from heavy-duty American steel and designed to last a lifetime.

This complete walkthrough can help you assemble your grill with confidence. Or download the manual here.

Tools Required

5/16” socket
3/8” socket
7/16” wrench
Nut driver or socket wrench
Utility knife or box cutter

Step 1: Prepare the Area

Set the pallet on a flat, level surface. With help, tilt the box upright so arrows point up. Remove the pallet and clear the workspace.

Note: The box may weigh up to 350 pounds. Lift with caution.

Step 2: Unbox the Grill

With the box standing upright (as shown in the manual), open what was originally the bottom of the shipping box. Carefully cut the tape and fold back the flaps to access the internal boxes. Do not remove the main chamber or foam packaging—this structure provides stability for the rest of the assembly process.

Step 3: Inventory the Parts

Once the box is open and the inner boxes are visible (see FIG 2), you'll find multiple labeled packages inside the crate. While Box 1 and Box 2 contain the main frame components, the full inventory includes:

Box 1: Hardware pack (A), Bottom shelf (B), Yoder logo skirts (G), Long skirts (H)
Box 2: Legs (C, D), Casters (E), Wheels (F)
Box 3: Located inside the cook chamber, contains the operations manual and final small parts
Box 4: Additional metal parts or brackets
Box 5 & 6: Interior parts and accessories (e.g., grates, diffuser, possibly wrapped behind one another)
Box 7: Smaller boxed accessories, such as shelves or drip trays

Confirm you have axle pins, cotter pins, sheet metal screws, whiz bolts, and hex nuts. View the official PDF here.

Step 4: Build the Base Frame

Place bottom shelf label-down on Box 1.
Insert Legs C and D into notched cutouts. The notches are labeled to match each leg.
Secure each leg with four A3 sheet metal screws.

Step 5: Add Wheels and Casters

Insert axle pin through wheels and legs, secure with cotter pins.
Insert caster legs and secure with four A3 screws each.

Step 6: Attach Skirts

Yoder Logo Skirts: Align with the bottom holes only. Hand-tighten with A4 bolts and A5 nuts.

Long Skirts: Repeat process using the bottom holes only. You may need to gently pull the legs outward to align the holes.

Step 7: Mount the Grill Chamber

With the stand fully assembled and wheels facing down, lift the entire stand frame and carefully guide it onto the receiving brackets located underneath the pellet cooker (see manual figures 18 and 19). This means the cart is being added to the chamber—not the other way around. Once aligned, fasten each leg into the mounting brackets using two A4 bolts and two A5 nuts per leg. After all bolts are installed, tighten all connections securely.

Step 8: Remove Packaging and Tilt Upright

Cut both vertical edges of box. Fold flap down. With help, tilt the grill forward until wheels contact the ground. Secure wheels and tilt upright.

Step 9: Final Setup

Box #3 is located inside the pellet hopper and contains your operations manual and final parts. Open the hopper and locate Box 3. Install grates and trays. Refer to the operations manual for startup instructions.

Burn-In Procedure

Fill hopper with BBQr's Delight Competition Blend Pellets.
Set grill to 350°F and run for 60 minutes.
Let cool, then season grates with food-safe oil..

Recommended Accessories for the YS640s

GrillGrate Panels for YS640s – Improve heat retention and searing power.
Grease Shield for YS640/YS640s – Protects your grill exterior from excess grease buildup.
Cast Iron Griddle for YS640 – Ideal for breakfast, burgers, and high-heat cooking.
Stainless Steel Front Shelf for YS640s – Adds durable prep space and easy cleanup.
Stainless Steel Side Shelf for YS640s – Easy to clean and weather-resistant.

Frequently Asked Questions

How long does assembly take?: About 60 to 90 minutes with two people.
Can one person assemble it?: It’s not recommended due to the weight of the chamber.
Is the chamber pre-assembled?: Yes, only the cart requires assembly.
What’s the difference between YS480s and YS640s?: Cooking capacity. All other components are the same.