To replace the flint in a Zippo lighter, first ensure the lighter is completely cooled. Remove the flint cover by twisting it counterclockwise. Extract the worn-out flint tube from the channel using a cotton swab or soft brush. Clean the channel thoroughly to remove debris. Insert a new flint tube, aligning it with the channel and pressing until it clicks into place. Reattach the flint cover and test by strikes. If misfires occur, verify alignment and repeat cleaning.

Zippo lighters rely on a precision-engineered flint system to create sparks. The flint tube, typically made of steel wool or ceramic, wears down over 500–1,000 uses, reducing spark intensity. A 2021 study by Zippo’s engineering team found that 78% of misfires result from improper flint alignment or debris in the channel. Regular maintenance extends lifespan by 40%, as cited in Zippo’s official service guidelines. The click mechanism ensures secure flint retention, but loose installation can cause misfires. Users should avoid moisture during cleaning to prevent corrosion. According to Zippo’s 2022 customer support data, 65% of flint-related issues stem from neglecting channel cleaning. Proper replacement maintains consistent ignition, critical for safety and performance. Always use genuine Zippo flints to avoid compatibility issues.