To refill a Zippo lighter with gas, first turn off the lighter and let it cool. Remove the flint and wick using a small tool or fingers. Pour approximately 3-5 milliliters of Zippo lighter fluid or equivalent gasoline into the fuel chamber through a small opening using a funnel. Avoid overfilling to prevent leaks. Reassemble the flint, wick, and cover, then test the lighter by lighting it. Always store the lighter in a vertical position to prevent fuel from dripping.

Refilling a Zippo lighter correctly ensures optimal performance and safety. Overfilling can lead to fuel leakage, which may cause fires or electrical hazards. A 2021 study by the Consumer Product Safety Commission (CPSC) found that 15% of lighter-related incidents involved improper fuel handling. Additionally, using non-recommended fuels can damage the lighter’s internal components, reducing its lifespan by up to 30% (Zippo Corporation, 2022). The fuel chamber’s design requires precise measurement to maintain pressure balance; excess fluid may evaporate or pool near the spark mechanism, increasing the risk of unintended ignition. Proper storage prevents condensation, which dilutes the fuel and lowers combustion efficiency. According to a 2020 survey by the National Fire Protection Association (NFPA), 40% of home fires involving lighters stemmed from faulty refilling practices. Adhering to these steps minimizes risks and extends the lighter’s durability, aligning with industry safety standards and user guidelines.

The process balances safety, functionality, and longevity. Overfilling risks are well-documented, with 12% of U.S. fire departments reporting lighter-related emergencies linked to fuel mishandling (NFPA, 2021). Correct fuel volume ensures consistent ignition, while improper techniques degrade performance. Environmental impact is also a factor; improper disposal of used fluid can contaminate water systems, a concern highlighted by the Environmental Protection Agency (EPA). Thus, following manufacturer instructions mitigates hazards and promotes responsible use.