Broil King Baron 490 X Shadow

The Baron 490 X Shadow is built by the Onward Manufacturing Company, a Canadian family business that, according to its own company history, has existed since 1906 and switched to grills under the Broil King brand in 1985. According to the manufacturer, Broil King gas grills are made in Waterloo (Ontario), Huntington (Indiana) or Dickson (Tennessee), from domestic and foreign components. In the German manufacturer shop this grill carries the item number 674182; the assembly instructions (Rev. A, 02/26) list it under the model numbers 6741-82 and 6741-83.

In our gas grills category it belongs to the four-burner models with a rotisserie. Broil King sells a pellet module for the Baron 490 X; what the X in the name means is not explained by the manufacturer. Our price box lists it at Santos Grills at approx. €1,189. Broil King had marked it as “Coming soon” in its own shop on 02.11.2026.

Burners, grates, housing: what is built in

Under the lid are four Dual-Tube stainless steel bar burners with a combined 11.4 kW. Two further burners do not act on the grate: the rotisserie burner on the back wall with 4.4 kW and the side cooktop with 2.7 kW. Above the main burners sits the stainless steel Flav-R-Wave vaporising system, on top of it four Flav-R-Cast cast grates with a matt enamel finish. The instructions rule out lava stones, ceramic stones or any vaporising system other than the built-in one.

Broil King states the main cooking area as 65 x 44.3 cm and 2,729 cm²; the short list on the same product page says 65 x 44.4 cm. According to the dimension graphic of the Baron 400 X series, each of the four grate segments is 15.4 cm wide and 44.3 cm deep. Above it hangs a stainless steel secondary rack, 65 x 18.5 cm and 1,203 cm² in size. Here the manufacturer’s arithmetic does not add up: main and secondary rack together come to 3,932 cm², yet the product page speaks of 4,679 cm² including the secondary rack.

Control is via Linear-Flow gas valves with the 180-degree Sensi-Touch control; the control knobs are illuminated. Ignition is electric with Sure Lite, also on the rotisserie burner. The Deluxe Accu-temp thermometer sits in the lid.

The lid is double-walled and black enamelled, with cast aluminium side panels and a stainless steel handle. The cooking chamber itself is a Therma-Cast housing made of cast aluminium. The control panel, the fold-down side shelves with their accessory hooks and the closed cart with two doors, which has room for an 11 kg gas cylinder, are black powder-coated. So this model does not have stainless steel side shelves.

Four lockable castors carry the whole thing. How heavy it is is stated differently in two places: 74.0 kg in the dimensions tab of the product page, 78 kg in the series dimension graphic. The same graphic gives the assembled size as 145 cm wide, 61 cm deep and 118 cm high; with the side shelves folded down it is 92 cm wide. According to the product page, a rotisserie set with electric motor as well as hose and pressure regulator are included in the delivery.

In detail: how much power reaches the grate

According to the table in the pellet module manual, all burners together come to 18.5 kW at a gas consumption of 1345 g per hour, stated for model 6741-83. This total is of little use for comparison with other grills, because the side cooktop and the rotisserie burner do not heat the grate. According to the manufacturer, the main burners deliver 11.4 kW.

The main burner output per square centimetre of grate is more meaningful. With the manufacturer’s figures, the Baron 490 X Shadow reaches just under 4.2 W per cm², i.e. 11,400 W over 2,729 cm². According to broilking.de, the Crown 490 Shadow has the same 11.4 kW but a stated main area of 2,864 cm², which gives just under 4.0 W. On the Regal 590, 16 kW are spread over 4,032 cm², also just under 4.0 W. We calculated this ourselves.

What is odd about this: according to their product pages, the Crown 490 Shadow and the Baron 490 X Shadow have the same grate size of 65 x 44.3 cm, and yet the Crown shows the larger area. We found no explanation for this in the documents. The Baron’s lead in output per area is so small anyway that we would not count it as a reason to buy.

What the control settings mean is described by the manual for Broil King gas grills in general, not for this model, in each case with the lid closed: HIGH approx. 370 to 400 °C, Medium/High approx. 320 °C, Medium approx. 230 °C, Medium/Low approx. 200 °C and Low approx. 155 to 175 °C. Wind and outside temperature shift the values. Preheating takes approx. 10 minutes with the lid closed on a medium to high setting. On HIGH, every burner port should burn with a flame approx. 1.5 cm high; that is the quickest way to see whether a burner is working cleanly.

Four individually controlled burners allow a direct and an indirect zone side by side; our guide to direct and indirect heat explains the principle. In the manual it reads like this: the outer burners run on a low to medium setting, the middle one(s) stay off, and the lid is closed. A drip tray is never used without liquid; 1 to 2.5 cm of water belongs in it.

Is the Baron 490 X Shadow a pellet grill?

Not from the factory, it is a pure gas grill. It only burns pellets with the Pellet Module 400 (item 674005EU), which Broil King sells separately for €649. According to the manufacturer, the module fits the pellet-ready grills of the Baron 400 series.

We would clarify one thing before buying. The word pellet-ready does not appear anywhere on the product page of the 490 X Shadow itself. The connection is only documented by the module’s manual (60094-40DE, Rev. C, 03/26), whose model table contains the number 6741-83. The grill’s assembly instructions, on the other hand, show two numbers, 6741-82 and 6741-83, and what distinguishes them is not stated in any of the documents. So ask the dealer which version you will get, and have them confirm that the module fits it.

By the way, the module changes nothing about the gas control. According to the manual, its iQue control regulates only the wood pellet burner; you continue to set the gas burners by hand. On top of the grill (approx. €1,189 in our price box) comes the module at €649 in the Broil King shop. How pellet fire works in general is covered in the guide to the pellet grill.

Rotisserie and side cooktop

The rotisserie burner has its own Sure Lite ignition, and the rotisserie set and motor are included. According to the manual, the spit carries no more than 7 kg.

For planning a barbecue evening, a warning from the same manual counts for more: the main burners must not be operated at the same time as the rear burner, and before the rear burner runs, the warming rack comes out. A roast on the spit while vegetables cook on the grate next to it is therefore out of the question.

Pots with a diameter of at most 23 cm and at most 7 kg are allowed on the side cooktop. If you fold down the side shelf with the cooktop permanently, the manual advises detaching the gas hose of the side burner so that it does not kink.

Gas, power and siting according to the instructions

The product page links a series manual for several Broil King ranges (20094-40DE/EU50, Rev. F, 01/22), whose model table does not contain the numbers 6741-82 and 6741-83. We nevertheless reproduce its safety rules closely to the wording, because Broil King assigns it to this grill. Where the newer pellet module manual differs, this is noted.

The title page names butane or propane of category I3P(50); for Germany and Austria, propane at 50 mbar applies. An unregulated gas supply must never be connected. The cylinder always stands upright in the cart, easy to reach for changing and emergency shut-off. On the size, the sources contradict each other: the product page and the 01/22 manual state 11 kg and exclude larger fill quantities, while the pellet manual speaks of 15 kg. We would stick with 11 kg, since the cart is specified for that.

It is similar with the hose. The old manual requires a length of at least 600 mm, while the new one allows at most 600 mm. It belongs away from hot zones and sharp edges and must be neither twisted nor kinked. It is checked for damage and brittleness at every cylinder change, but at least twice a year. If it is cut, abraded or otherwise damaged, the grill must on no account be put into operation until a new hose is fitted.

You check for gas leaks before the first start-up, at every cylinder change and every time a screw connection has been separated. While doing so, you do not smoke, keep open flames away and always work outdoors. A soap solution of one part water and one part liquid soap goes onto all connections; bubbles show a leak. If it persists, the grill must under no circumstances be used any further, and you contact the dealer. You change the cylinder only in an environment without fire risk. Its connection has a left-hand thread, you check the sealing ring beforehand, and you must on no account turn the pressure regulator.

If you smell gas, the manual’s sequence applies: shut off the gas supply to the appliance, extinguish any open flames immediately, open the lid, and if the smell persists, call the dealer or customer service. Shutting down is done in two steps, first close the gas cylinder, then the knobs to OFF. After every grilling session the cylinder stays closed.

The grill may only be operated outdoors; it is not permitted in enclosed spaces. The manual requires at least 76 cm clearance to combustible material, also in front of large glass doors and windows; the pellet manual specifies 76 cm to each side and to the rear. It does not belong under a combustible roof, nor near petrol, paints, flammable gases or flammable liquids. Nozzles and openings for gas, flame and air must always stay clear. According to the manual, anyone who covers slots, holes or openings at the front or bottom of the grill with aluminium foil risks overheating and carbon monoxide poisoning. According to the pellet manual, it should not run at all in strong wind. It is neither moved nor transported during operation, and because accessible parts get very hot, the instructions advise keeping children away.

The grill needs electricity for the knob lighting. The manual describes a transformer for this with 230 to 240 V and 50 Hz at the input and 12 V at 7500 mA at the output. You may only operate it on a residual current device, and an extension cable must be CE-certified and intended for outdoor use. You never immerse cables and plugs in water. When not in use and before cleaning or maintenance, you disconnect the power once the grill has cooled down. A defective supply cable is replaced before the next use and never hangs over hot parts.

Cleaning, care and maintenance

The cast grates must never air-dry and never go into the dishwasher. Before and after every grilling session they are brushed and oiled, and afterwards you carefully search them for left-behind bristles. To burn off, you set the grill to HIGH for approx. 15 to 20 minutes with the lid closed. The grease tray sits under the grill housing in a pull-out grease catch pan and should be cleaned regularly.

White oxidation can form on the cast aluminium outside; according to the instructions it comes off with soapy water. You touch up paint damage with an oven paint spray that withstands at least 400 °C.

At least once a year and after every rest period of more than 30 days, you check and clean the burners, venturi tubes, line and pressure regulator. With the venturi tubes, this is more than cosmetics. Spiders, insects and their nests can block them, the gas backs up and can catch fire in a place where it has no business. The manual names four signs: a smell of gas, the grill does not reach the required temperature, it heats unevenly, or the burners make popping or bubbling noises. Then you turn off the gas, let the grill cool down, remove the burners, clean the tubes with a pipe cleaner or venturi brush and put them back exactly onto the nozzles.

According to the manual, DIY work goes no further than that. You may only adjust the flame pattern yourself; any other maintenance and modification belongs to a qualified technician or customer service. You expressly do not repair problems with the pressure regulator, line, burners or valves yourself. More on basic cleaning can be found in our guide cleaning a gas grill.

Warranty, spare parts and open points

How long Broil King guarantees is answered differently by three manufacturer sources. The English 2026 warranty graphic on the product page states 25 years on the cooking chamber, 15 years on components and 5 years on the grates. The pellet manual from 03/26 lists for the Baron 25 years on the lid and die-cast aluminium cooking chamber, 15 years on cast grates, Flav-R-Waves and main, side and rear burners. The 01/22 manual states lifetime on the lid and die-cast aluminium, 2 years on the cast grates, 3 years on the Flav-R-Wave, 10 years on Dual-Tube and rear burners, 2 years on the side burner and on other parts. We advise getting the valid periods from the dealer in writing before buying.

The conditions are in the 01/22 manual. Only the privately used grill of the first buyer is covered, and registration at broilking.de must take place within 24 months of purchase. After two years, in a warranty case you bear, among other things, shipping and transport costs, assembly and service calls yourself. Parts from other manufacturers cost you the warranty. You get original spare parts via the dealer, a service centre or Broil King directly; the manufacturer shop has a spare parts search for this.

After all the documents evaluated (product page, both manuals, assembly instructions, series and warranty graphics), the following remains open:

• a heat-up time to a specific temperature and a maximum temperature specifically for this model
• the gas consumption of individual burners, there is only the total value
• the material of the burner cover, ignition rail and grease pan, and the material thickness of the lid and housing
• dimensions and weight specifically for the 490 X Shadow, the graphic applies to the whole Baron 400 X series
• since when the model has existed and in which of the three plants it is made
• how many people the grate is intended for
• operation with natural gas in Germany
• a matching cover with item number

What else is worth considering?

The prices are guide values from our price box and change. The technical details in the column The difference come from broilking.de and napoleon.com. Our rating summarises the data comparison editorially; we have not measured anything on any of the four grills.

When the Baron 490 X Shadow fits and when another grill does

First the site. With the shelves unfolded the grill is 145 cm wide, and because the manual requires 76 cm clearance to combustible material on both sides, in front of a wooden wall or hedge you need just under 3 m of width (our calculation: 145 plus twice 76 cm). Toward the back, another 76 cm is added to the 61 cm depth. From our point of view that does not fit on a small balcony, quite regardless of what landlord or house rules allow.

Then the pellet question. If you will never smoke with pellets, with the Baron you pay for an option you do not use. According to Broil King, the Crown 490 Shadow has the same four burners with 11.4 kW, the same 4.4 kW rotisserie burner and the same 2.7 kW side cooktop, rotisserie set and motor included, and is listed in our price box at approx. €996, the Baron at approx. €1,189. In the Crown’s equipment list there is neither a double-walled lid nor knob lighting, and its secondary rack is enamelled instead of stainless steel.

Within the Baron range there is also the Baron 490 without the X. Its control panel and side shelves are stainless steel, and Broil King states the cooking area with secondary rack as 3,932 cm². Pellet compatibility is documented in the documents only for the X models. It is not yet in our catalogue.

If you often grill for large groups, the Regal 590 is the logical next step, with five burners and a grate of 80 x 48.8 cm. It is listed in our price box at approx. €1,649, the Baron at approx. €1,189. If instead you want an infrared zone for searing and can do without the supplied spit, the Napoleon Rogue PRO-S 525 is worth a look, listed in our price box at approx. €1,299.

For the Baron, a gas cylinder and a cover also belong in the budget; neither is included in the delivery. For consumption, your own back-of-the-envelope calculation helps: if the 1345 g per hour is divided in proportion to output, roughly 830 g per hour fall to the four main burners. An 11 kg cylinder would then last a good 13 hours with all main burners on HIGH, correspondingly longer at reduced heat. This split is ours; Broil King gives only the total value for the burners.

The grill is wrong for you if you want to move it often: 74 to 78 kg on four castors is meant for the patio, not for switching between garage and garden, especially as the gas cylinder has to be closed and removed every time it is moved. And anyone who plans a roast on the spit and side dishes from the grate at the same time will not get there with the Baron because of the rear burner rule. If you are still undecided between grill types, the Grill Finder pre-sorts the selection according to your answers.