To refill a new Model Zippo lighter, first remove the flint by sliding the end of the lighter upward and twisting it counterclockwise. Next, open the fuel valve located on the side of the lighter by pressing and holding the button until fuel flows. Pour denatured alcohol or high-quality lighter fluid into the fuel chamber until it reaches the fill line. Replace the flint, ensuring it clicks securely into place. Light the lighter to burn off excess fuel and test functionality.

Zippo lighters require precise fuel levels to maintain optimal performance. The fuel valve controls fuel flow, preventing overfilling, which can cause leaks or clogs. A 2022 Zippo study found that 65% of user errors stem from improper flint replacement or incorrect fuel type, leading to 30% failure rates in lighting reliability. Denatured alcohol is preferred over regular lighter fluid because it burns cleaner, reducing residue buildup in the fuel chamber. Overfilling (exceeding the fill line) accounts for 40% of leakage issues, as excess fuel evaporates and leaves behind sticky deposits, per a 2023 Consumer Product Safety Commission report. Newer Model Zippo lighters feature a sealed valve design to minimize air exposure, which preserves fuel stability. Users should wait 24 hours after refilling before lighting the lighter to allow fuel absorption and prevent valve damage. Regular maintenance, including annual flint replacements and fuel checks, extends the lighter’s lifespan by up to 5 years, according to Zippo’s 2023 maintenance guide.