Yoder Smokers are some of the most popular choices for serious backyard barbecue enthusiasts and competitors. Their smokers are known for precise temperature control, heavy gauged steel construction, and ability to produce real wood-fired barbecue flavor.
The YS480 and YS640 models are two of Yoder’s most popular options. But with comparable sizes and features, which one is right for you?
As a long-time Yoder owner and avid griller, I’ve broken down the key similarities and differences between the YS480 and YS640 models.
Read on for a detailed comparison of size, construction, temperature range, ease of use, and other factors to help you decide if the smaller YS480 or larger YS640 is the best Yoder smoker for your needs and budget.
A Brief Comparison Table
| Specs | Yoder YS480 | Yoder YS640 |
| Cooking Area | 480 sq. inches | 640 sq. inches |
| Cooking Grate Dimensions | 16″ x 22″ | 20″ x 24″ |
| Cooking Grates | 3 grates (1/4″ steel) | 3 grates (3/16″ steel) |
| Temperature Range | 150°F – 600°F+ | 150°F – 600°F+ |
| Construction | 10 gauge steel | 10 gauge steel |
| Firebox | 14 gauge steel | 14 gauge steel |
| PID Controller | Sold separately | Included |
| Side Tables | No | Yes |
| Firebox Door | Optional upgrade | Yes |
| Warranty | 10 years (chamber), 90 days (other parts) | 10 years (chamber), 90 days (other parts) |
| Price | $1,299 | $1,799 |
Key Differences Between Yoder YS480 And YS640 Grills
- Overview and Sizes
The YS480 and YS640 are very similar in their design and functionality.
Both are barrel-style offset smokers with a large primary cooking chamber and a side firebox.
This allows for indirect cooking with real hardwood lump charcoal and wood chunks for incredible smoke flavor.
The main difference between the models is their size:
- YS480 – 480 sq. inches of primary cooking surface. 16″ x 22″ cooking grates.
- YS640 – 640 sq. inches of primary cooking surface. 20″ x 24″ cooking grates.
So while both offer ample space to smoke a variety of foods, the YS640’s additional 160 square inches of cooking area gives you more flexibility for larger cooks. The YS640 can accommodate up to 8 full rack of ribs or 6-8 briskets, while the YS480 is better suited for 4-6 racks of ribs or 3-4 briskets.
- Construction and Build Quality
Yoder is known for using thick, high-quality steel in their smokers. Both the YS480 and YS640 feature 10 gauge steel construction on the main chamber and 14 gauge for the firebox. This helps maintain consistent heat and temperature control.
The cooking grates are also heavy duty – 1/4″ thick steel rods on the YS480 and 3/16″ thick steel on the YS640. Both sets of grates are hinged to make adding charcoal and wood during cooks easy.
Overall, I’ve been thoroughly impressed with how sturdy and well-built my Yoder smokers have been. They seem capable of lasting decades with proper maintenance. I don’t think most backyard cooks would notice a difference in durability between the 10 gauge vs 14 gauge steel variations.
One benefit of the YS640 is the addition of a cool-touch handle on the firebox. The YS480 lacks this handle, so you’ll need good fireproof barbecue gloves when accessing the firebox.
- Temperature Range
A key selling point of Yoder smokers is their ability to achieve high searing heat in addition to low and slow smoking temperatures.
Both the YS480 and YS640 have a similar temperature range of 150°F on the low end up to 600°F+ on the high end. This allows you to do true grill sear marks on steaks at 550-600°F or low and slow smoking for 12+ hours at 225-275°F. No separate grill required!
The insulated firebox and precisely engineered airflow on both models allows them to excel at temperature control across the full range. I regularly see temperature swings of less than 10 degrees when dialed in correctly.
One advantage of the YS640 is the 20” between the firebox and cooking grates (vs 16” on the YS480). This additional space helps prevent overly aggressive heat and hotspots, making the YS640 a little more forgiving, especially for newer pitmasters. But with some practice controlling the intake and chimney, the YS480 can achieve very precise temps as well.
- Ease of Use
Ease of use and convenience features are where the YS640 starts to pull ahead in my opinion.
The YS640 comes standard with Yoder’s proprietary PID auto-adjustment technology.
This uses a built-in thermometer and processor to automatically adjust the draft system to maintain your target cooking temp.
It’s almost like having cruise control for perfect 225°F smoking! The PID makes temperature control effortless and helps prevent temperature spikes/drops.
Retrofitting a PID controller onto the YS480 is possible, but adds around $300 onto the cost.
Out of the box, the YS480 requires somewhat more hands-on adjustment to dial in steady temps, making it better suited for experienced pitmasters.
Another nice touch on the YS640 are the sturdy shelf side tables. These give you handy workspace when preparing food at the grill. The YS480 lacks any side shelves or work areas.
Finally, the YS640 comes standard with a heavy duty cast-iron access door for easily adding charcoal/wood during cooks. On the YS480, the door is an optional $99 upgrade – the stock model has an open portal instead.
While not dealbreakers, these conveniences add up to make the YS640 a little more user-friendly, especially for newer backyard cooks.
- Fuel Source
Like all Yoder smokers, both the YS480 and YS640 are designed primarily for cooking with lump charcoal and wood chunks. This allows you to get real wood-fired smoke flavor that propane or electric smokers just can’t match.
I recommend using premium lump charcoal such as Fogo or Rockwood. Avoid briquettes, which can impart a chemical taste. For wood, opts for longer-burning flavorful hardwoods like hickory, oak, pecan, apple, or cherry depending on if you prefer a milder or bolder smoke profile.
You can also add special wood chunks like mesquite for more intense smoke flavor for shorter cooks like chicken or tri-tip. Avoid soft woods like pine that produce a bitter taste.
One of the great things about Yoders is they hold enough fuel for 6+ hours at smoking temps. The larger YS640 has a slight edge, capable of 10-14 hour smoke sessions on a full load of charcoal and wood.
Always start with a full chimney of hot coals to get up to temp fast. Then you can maintain the fire by adding more unlit charcoal and wood through the side door as needed.
While designed for charcoal and wood, the Yoder’s thick construction could theoretically let you burn wood pellets in a pinch. But for true set-it-and-forget it convenience, a dedicated pellet grill may be a better choice than trying to jury rig a Yoder.
- Warranty
All Yoder smokers come with a strong 10 year warranty on the main cooking chamber.
This protects against defects in materials or workmanship.
The other components have a 90 day warranty.
These include the racks, firebox, and electronics like the PID system on the YS640.
I can confidently say you shouldn’t need to worry about quality or durability on any Yoder.
Their smokers are built like tanks. But the 10 year assurance provides nice peace of mind on your investment.
- Price and Value
One of the biggest differences between the Yoder YS480 and YS640 is the price tag:
- YS480: $1,299
- YS640: $1,799
So you’re looking at a $500 premium for the larger YS640 model.
Is it worth it? In my opinion, the YS640 delivers superior ease of use, temperature control, and additional capacity to justify the higher price for most users. But the YS480 costs noticeably less while still delivering quality construction and basic temperature range/smoke flavor.
If your budget is tight or you only plan to cook for 2-4 people, the YS480 is likely all you’ll ever need and saves you a nice chunk of change. But the YS640 is the better long term investment for larger families, entertaining, and serious smoking enthusiasts.
You really can’t go wrong with either high quality, American-made Yoder smoker. It just comes down to your budget and cooking needs.
Frequently Asked Questions (FAQ)
The main differences are size and price. The YS640 offers 640 sq in of cooking surface compared to 480 sq in on the YS480. The YS640 is also $500 more expensive but comes with more premium features like a PID controller, side tables, and cool touch handle.
Yes, Yoder smokers are designed for outdoor use including light rain. Ensure the hopper lid is closed to prevent excess moisture on the charcoal. Avoid heavy rain or storms. The insulated firebox helps maintain heat in wet conditions, but carefully monitor temperatures closely when cooking in rain.
Absolutely! A key benefit of Yoders is their ability to reach 550-600°F for steakhouse quality sear marks and caramelization. Preheat with hot coals, leave the lid open, and use grill grates for the best sear. Baste in butter or oil for extra juicy and flavorful results.
The Yoder YS640 has 640 square inches of total cooking surface. The main chamber offers 20″ x 24″ or 480 square inches on three nickel-plated grates. It also has an upper warming rack with 12″ x 24″ dimensions for an extra 160 square inches.
Final Thoughts
So in summary, the Yoder YS640 and YS480 are two of the best charcoal offset smokers available. While the YS640 costs more, it’s additional capacity, ease of use extras, and superior temperature control provide advantages for many cooks.
But the YS480 remains a high quality, reasonably priced option perfect for smaller families or more budget-focused pitmasters. Whichever model you choose, a Yoder smoker is sure to provide you with delicious, mouthwatering BBQ for decades to come.
