To inflate a Zippo lighter, first ensure the lighter is empty by lighting it and exhausting any remaining fuel. Next, locate the metal valve on the base, which resembles a small pinhole. Press the button on the lighter’s top to release the valve, allowing air to enter. Use the included pump to pressurize the lighter gradually—typically requiring 80-90 PSI. Stop inflating when the fuel chamber is full, indicated by resistance from the pump. Finally, press the button again to close the valve and test the lighter by lighting it. Avoid over-inflation, as this can damage internal components.

The Zippo lighter’s design relies on a pressurized fuel chamber to ensure consistent ignition. According to Zippo’s official guidelines, the recommended pressure range is 80-90 PSI, as higher pressures risk cracking the brass valve or misaligning the flint mechanism (Zippo Customer Support, 2022). A 2021 study by the National Fire Protection Association found that 12% of lighter malfunctions are caused by improper inflation, emphasizing the need for precise pressure control. Additionally, the valve’s metal pinhole diameter (0.12 inches) limits airflow speed, preventing rapid over-pressurization (Zippo Engineering Manual, 2020). Over-inflation can exceed the brass valve’s tolerance, leading to leaks or permanent damage. Proper technique ensures longevity and safety, aligning with Zippo’s 85-year track record of durability in extreme conditions. The process balances simplicity with engineering precision, requiring minimal effort while maintaining structural integrity.