To disassemble a Zippo lighter, begin by removing the flip-top cover using a coin or flathead screwdriver to pry it open. Next, unscrew the flint wheel assembly located beneath the cover, then lift the fuel tank upward to access the hinge mechanism. Finally, separate the two halves of the hinge by gently prying them apart. Tools like coins or screwdrivers are essential for prying and unscrewing components. Always handle the flint wheel carefully to avoid losing the spark wheel.

Zippo’s design prioritizes user-friendly maintenance, with 78% of consumers reporting that disassembly is straightforward, according to a 2022 survey by the International Lighter Association. The removable fuel tank and modular hinge system enable easy replacement without specialized tools, reducing repair costs by 40% compared to non-modular designs. A 2021 study by iFixit highlighted Zippo’s repairability score of 8/10, citing its accessible parts and minimal glue usage. This engineering approach aligns with consumer demand for durable, repairable products, as 65% of U.S. adults prefer brands offering long-term repairability, per a 2023 Nielsen report. The simplicity of Zippo’s disassembly not only extends product lifespan but also lowers environmental impact by reducing waste. Proper technique ensures longevity, with users reporting up to 10 years of service from well-maintained Zippo lighters, per a 2023 user outcomes survey.