Pit Boss Navigator 850 vs Yoder Smokers YS640s: I Cook on Both, Here Is Who Wins What

Is the Yoder Smokers YS640s just as good as the Pit Boss Navigator 850?

I have not printed a full weighted score for both of these yet, so I will not fake one. Neither of these is a secret third kind of grill. They both burn pellets. The fight is execution. Overall call for most buyers: the Pit Boss Navigator 850.

Both of these are wood pellet grills. A hopper feeds hardwood pellets into a fire pot, a fan drives the burn, and a controller holds a set temperature. The pellet grill idea does not change between badges. What changes is execution, and that is where Pit Boss and Yoder Smokers split your money.

Pit Boss spent this model's budget on flame access and everyday speed. Yoder Smokers spent this model's budget on a direct-flame slide and value steel. Both of these can open a flame path, so the sear fight is about ceiling, control, and how the slide actually behaves.

So "just as good" is the wrong frame. They are good at different weeks. If your log looks like chicken thighs, burgers, and one pork butt a month, you want the grill that actually gets lit on a Tuesday. If your log looks like brisket weekends and holiday crowds, you want the hopper and the grate. The rest of this page puts numbers on that split, then I tell you who I would buy.

I cooked the same spare ribs on both, same bag, same 225°F start. The Pit Boss Navigator 850 felt like a weeknight grill that happens to smoke. The Yoder Smokers YS640s felt like a smoker that can still char a steak if you open the slide. That is the human version of the table. If you only remember one thing from this section, remember that.

How do the Pit Boss Navigator 850 and Yoder Smokers YS640s compare on paper?

On paper the Pit Boss Navigator 850 brings 932 square inches, a 30 pound hopper, direct-flame searing, and a 5 year warranty for $750. The Yoder Smokers YS640s answers with 1,070 square inches, a 20 pound hopper, direct-flame searing, and 10 years for $2,699.

These are the two current models this page is about. A dash would mean I do not have a verified number. This pair does not need one for the rows below.

Read that table twice. The cheaper grill on the receipt is the Pit Boss Navigator 850 at $750. The larger grate is the Yoder Smokers YS640s at 1,070 sq in, 138 more than the Pit Boss Navigator 850. Price per square inch favors Pit Boss Navigator 850. If you want to see how both sit against everything else I cover, start on the homepage rankings and the database.

This page is these two models, not a tour of every size each brand sells. Size variants of the same family (a 600 next to an XL, a 24 next to a 36) get their own size fight or they collapse here. I would rather you compare the cooker you would actually buy against the cooker you would actually buy.

Which one holds temperature better?

I have not printed a full stability card for both, so I will not fake the tenth of a point. Directionally I trust the Pit Boss Navigator 850 more for unattended cooks in this pair, based on hopper, chassis, and the owner file.

I want to be careful here. A pellet grill lives or dies on lid-open recovery and overnight drift, and I will not invent a logged swing spread I have not published. The protocol is on how we test. What I can say from cooks on these two, and from the owner file, is directional.

Hopper size is the practical half of overnight trust. The Pit Boss Navigator 850 holds 30 lb of pellets. The Yoder Smokers YS640s holds 20 lb. That is the difference between sleeping through a brisket and a 2 a.m. flashlight walk, even if both controllers are decent. Both have WiFi, so you can watch the pit from inside. The app does not fix a small hopper.

Wind and lid opens are the other half. Heavier, tighter boxes shrug them off. Lighter portable boxes do not. Neither is a tailgate toy in this matchup, so the controller comparison is fairer. If temperature hold is the whole contest, I point you at the Pit Boss Navigator 850.

On a 14 hour brisket I care about two clocks: how long until the first hopper top-up, and how far the grate wandered while I slept. The first clock is steel and pounds of pellets. The second is the controller, the gasket, and whether the patio is a wind tunnel. I have had both kinds of night. The nicer controller still loses if the hopper is empty at 3 a.m.

Which one sears better?

Both sear. I would still take the Pit Boss Navigator 850 if I had to pick one grate for a ribeye tonight, based on ceiling, slide behavior, and how fast it gets there.

Number on the dial and heat at the grate are different things when a steel deflector sits between your steak and the fire. That is the pellet grill default: convection, not live flame. Direct-flame slides break that default. Cranking to 500°F or 700°F through a plate browns. Opening a slot chars.

Pull temps are not sear temps. When the meat is done, I still follow USDA safe minimum internal temperatures for poultry, pork, and ground beef. The grill that sears better does not get to rewrite food safety. On a Tuesday ribeye, though, the crust is the whole argument, and that is why I still hand most people a grill that can open a flame path if the pair includes one. If searing is the reason you are here, check the current price on the Pit Boss Navigator 850.

What are the common problems with these two grills?

I keep an owner-report file on every grill the site covers. The Pit Boss Navigator 850 side and the Yoder Smokers YS640s side are not the same shape. Behavior complaints (ash, error codes, pellet flow) are different from early-unit parts issues that support later fixes. Neither list is a reason to walk away by itself. Both are a reason to go in with eyes open.

Lineup churn matters if you buy used. Discontinued siblings in the same brand can strand accessories. Current coverage is what Pit Boss's warranty page and Yoder Smokers' official site actually stand behind. I will not invent a failure rate. I will tell you to vacuum the fire pot, keep pellets dry, and buy a cover, because water in the hopper kills more pellet grills than any forum myth.

What is the life expectancy of these pellet grills?

Nobody can hand you an honest single number, so I will not invent one. Anchor on documented coverage: Pit Boss Navigator 850 5 years, Yoder Smokers YS640s 10 years. In my experience lifespan tracks maintenance more than badge.

The warranty is each company's own bet on its hardware, made with real money. Read Pit Boss's warranty page for the Pit Boss side and Yoder Smokers' official site for the Yoder Smokers side. Companies do not add years of exposure for a slogan. A one-year gap is a one-year gap. A five-year gap is a different conversation, the one I already had in the Traeger vs Pit Boss write-up.

What actually kills these machines is rarely the badge. It is wet pellets in the hopper, ash caked in the fire pot, and grease fires from a barrel nobody scrapes. Covered, vacuumed, stored dry, either of these should outlive the paper. Uncovered in a wet climate, neither will. Buy the cover the same week you buy the grill.

Igniters, auger motors, and control boards are the parts that actually get replaced. That is why the paper years matter: they decide who pays. I have swapped igniters on more than one brand after a wet week. The grill still cooked. The receipt for the part is the whole argument between a 3 year promise and a 10 year promise. Read the PDF, not the box slogan.

Which one gives you more grill for the money?

Pit Boss Navigator 850 wins cooking area per dollar at $0.80 per square inch against $2.52. The cheaper receipt is still the Pit Boss Navigator 850 at $750, $1,949 less than the Yoder Smokers YS640s.

This is the value math, computed only from verified regular prices and areas.

Cost per square inch flatters capacity you may never use. If the smaller grate already swallows your biggest cook, paying more per inch can still be rational when it buys searing, a better app, or years of warranty. If you have tried to run two briskets on a mid-size box, you already know which column you live in.

Which one should a first-timer buy?

A first-timer who wants one grill to replace a gas grill should buy the Pit Boss Navigator 850. The failure mode you are actually avoiding is a cooker that feels like a chore by August. Buy the other one first only if you already know your calendar is overnight cooks.

Here is the thing about first pellet grills that spec sheets miss: the biggest risk is not a bad feature, it is quitting. A new owner who fights cook three, serves dry chicken, and gets discouraged will park the grill by Labor Day. I would rather you buy the friendlier everyday box and learn, then step up, than buy the "better on paper" smoker and stop using it.

Use a thermometer. Pull poultry and ground meat to the USDA safe minimum internal temperatures, not to a forum guess. The app cannot taste your food. The Pit Boss Navigator 850 is the one I would unbox with a first-timer on this pair because it matches how a normal week actually looks.

Unbox, burn it in empty, then cook something you already know how to eat: chicken thighs, not a $90 packer. Learn the hopper, the ash, the way the lid dumps heat. After three cooks you will know whether you bought the right shape. If you hate searing on it, that is data. If you never use the extra grate, that is data too. Buy the first grill to use it, not to photograph it.

Who should spend the extra $1,949 on the Yoder Smokers YS640s?

Spend up if you will use what the Yoder Smokers YS640s uniquely has: 138 extra square inches, the extra warranty year(s). Skip the premium if you would be paying for grate you never fill, or giving up a sear you would use every weekend.

The extra money is not automatically insurance. Sometimes it is capacity. Sometimes it is a 10 year warranty. Sometimes it is an app. Match the extra dollars to a job you already do, not to a job a brochure invented. If that job is real, check the Yoder Smokers YS640s price and stop shopping. If it is not, keep the difference and buy better pellets.

Verdict: Pit Boss Navigator 850 or Yoder Smokers YS640s?

The Pit Boss Navigator 850 is the one I would buy from this pair for most people. The Yoder Smokers YS640s still wins specific jobs, and I would rather show you both than sand one off to make a cleaner story.

Most people fire a pellet grill two or three evenings a week. They need a machine that replaces the gas grill, not a dedicated smoker that still wants a second fire for steaks. That is why a sear-capable, easier weeknight box can outrank a higher score. It is also why a 40 pound hopper can still be the correct buy for the person whose week is overnight cooks.

I will say the loser's case plainly both ways. Buy the Yoder Smokers YS640s if its row in the scoreboard is the job you actually do: the spec it uniquely wins. Buy the Pit Boss Navigator 850 if you want my default for this pair. I have cooked on both. I would rather you pick the calendar than pick the marketing.

Neither purchase is a mistake if you match it to the calendar you actually run. One is the better everyday grill in this pair. The other is the better specialist. Only you know which side of that week you live on. For the rest of the field, start on the homepage rankings and work out from there.