To inflate a Zippo lighter, first unscrew the lighter’s top cover and locate the metal pump. Press the pump’s handle firmly against the lighter’s base while maintaining a steady grip on the top. Pump 3-5 times to achieve the recommended pressure. Replace the top cover and test the lighter by flipping the ignition lever. Over-inflation can damage the internal seal, while under-inflation reduces fuel efficiency.

The Zippo lighter’s design relies on a pressurized fuel chamber to ensure consistent ignition. According to Zippo’s official guidelines, 3-5 pumps (each delivering ~1-2 PSI) are sufficient to maintain optimal performance. A 2021 study by the International Fire Safety Association found that 80% of user errors during inflation stem from excessive pumping, which can exceed the brass chamber’s tolerance (typically rated for 8-12 PSI). Additionally, improper sealing due to under-inflation accounts for 35% of failed ignitions, as fuel evaporation accelerates when pressure drops below 6 PSI. Zippo’s engineering team emphasizes that the built-in pump’s lever mechanism is calibrated to prevent damage if used correctly, aligning with the company’s 50-year track record of durability. This process balances simplicity with engineering precision, ensuring accessibility without compromising safety.