How to change the piezo igniter on a Jetboil Flash
Disclaimer:The guide below is based on my own experience of performing this task. I am not an engineer, nor do I claim this to be an approved method of performing this task. Anybody following this guide does so at their own risk, and at risk of invalidating the warranty of their product/s
I eventually found a replacement piezo at the Cotswold Outdoor store in Betws y Coed. As always, I find the staff at this particular store extremely helpful and knowledgable! Whilst working out how to replace the igniter unit I thought it would be worthwhile taking some photos and making this into a tutorial blog post…
A word of warning here – there are two type of spare igniter available for the Jetboil: the older type for the PCS/GCS and newer type for the Flash/Sumo/Zip etc. They look similar, but the one for the Flash has a flexible white wire instead of a stiff ceramic tube.
Step 1 – Disassemble Burner
The burner assembly has two main halves – a metal ring with attached burner, and plastic lower moulding with gas control valve and igniter housing.
The burner (make sure it is cold and disconnected from gas canister!!) can be pushed down and rotated in an anti-clockwise direction (grip plastic housing securely). The burner will separate from the lower control valve (the connector is a little like a bayonet light bulb fitting)and then the plastic upper ring will come away from the lower plastic housing.
The white/grey wire will then hopefully slide out of the ceramic tube that runs through the burner unit.
Step 2 – Remove old igniter
The old igniter cable will probably be quite brittle, so take care. You may need the old cable to calculate the length of the replacement one.
DO NOT USE ANY LUBRICANTS OR FLUIDS!!!
Step 3 – Prepare and fit new igniter
The new igniter will have an insulating sheath all the way to the end, unlike the one you have just removed. I laid them side by side an calculated how much insulating sheath to remove. The sheathing can be removed carefully with a sharp knife, but be very careful not to nick or damage the wire underneath.
Fit the igniter module in the plastic housing, ensuring there is a positive ‘click’ from the two plastic retaining clips.
Step 4 – Reassemble unit
Once you have stripped the wire, inserted the new igniter and cleaned out any crud then gently thread the wire up the ceramic tube in the burner.
Finally, bend over the top 4mm or so of the exposed wire end so it just overhangs the edge of the ceramic tube. By bending the white wire as it exits the ceramic tube underneath you can make sure this doesn’t move around too much. Make sure no exposed parts of the wire touch any of the metal parts of the burner – the way it works relies on there being a gap between the end of the wire and the surface of the burner.
Step 5 – Test ignite
If you now press the igniter you should see that familiar blue spark that shows it is working properly. Then attach a canister and test ignite.