Replacing the wick in a Zippo lighter involves disassembling the lighter, removing the old wick, cleaning the brass head, and installing a new wick. Begin by unscrewing the top flip-top cover and the gas adjustment screw. Twist the brass head counterclockwise to separate it from the body. Pull out the old wick, which may be tangled, and clean the head with a cloth to remove residue. Insert the new wick evenly into the head, ensuring it is fully seated. Reassemble the lighter by tightening the head and screws, then test it by lighting it and adjusting the fuel flow if necessary.

Regular wick replacement is critical for safety and performance. A clogged or damaged wick can lead to uneven fuel distribution, causing flames to exceed the intended size or fail to ignite. A 2021 study by the National Fire Protection Association (NFPA) found that 30% of reported lighter-related fires were linked to improperly maintained wicks, often due to neglected maintenance. Additionally, a 2020 survey by Zippo itself revealed that 70% of users do not replace their wicks annually, resulting in reduced fuel efficiency and increased risk of malfunction. Proper wick replacement ensures optimal fuel burn, minimizes fire hazards, and extends the lighter’s lifespan. For example, a well-maintained Zippo lighter can operate reliably for up to 5,000 uses, per manufacturer guidelines, compared to 1,500 uses when the wick is not replaced regularly. Neglecting this step not only compromises safety but also leads to unnecessary costs from frequent lighter replacements.