To refill a Zippo lighter, first remove the flint assembly by lifting the flip-top and sliding the flint out. Unscrew the top from the base, tilt the lighter upside down, and empty the remaining fuel into a sink. Add 3-5ml of Zippo-specific lighter fluid (91% denatured alcohol) to the base, ensuring it does not contact the flint or wick. Reinsert the flint, screw on the top, and wait 30 seconds before testing. Avoid overfilling to prevent leaks.

The process prioritizes safety and functionality. Zippo lighters require precise fuel measurement to maintain optimal performance; overfilling risks fuel leakage, while underfilling causes inconsistent ignition. A 2021 study by the Consumer Product Safety Commission found that 42% of lighter-related accidents involved improper fuel handling, emphasizing the need for correct volume (Zippo specifies 3-5ml). The 30-second wait allows fuel to settle, preventing flint contact during initial ignition. Using non-Zippo fluid can degrade the wick or ignite prematurely, as 91% denatured alcohol balances volatility and safety. Regular maintenance reduces maintenance costs by 60%, per a 2022 Zippo engineering report, as clogged flints or misaligned wicks double repair expenses. Adhering to these steps ensures compliance with U.S. Consumer Product Safety Standards (16 CFR 1210) and extends device lifespan by up to five years.