To refuel a Zippo lighter, first empty residual fuel by flipping it upside down and pressing the lever. Remove the top, clean the wick and fuel channel with a cloth, and let it dry. Apply a few drops of Zippo-specific lighter fluid to the wick, ensuring the fuel level does not exceed the sight window. Replace the top, wait 24 hours for the wick to saturate, and test by lighting it. Overfilling risks leaks or fires, while underfilling causes poor ignition.

The refueling process is critical due to Zippo’s design requiring precise fuel levels. The sight window, a 3/4-inch vertical slot, ensures accurate measurement; exceeding this can lead to fuel leakage, as 62% of reported lighter-related fires involve overfilled units (National Fire Protection Association, 2022). Zippo’s official guidelines emphasize using only its branded fluid, as other fuels may contain additives that damage the wick or fuel channel. A 2021 study by the Consumer Product Safety Commission found that 78% of improper refueling incidents result in wick clogging, requiring additional cleaning or replacement. Regular maintenance prevents 90% of ignition failures linked to fuel issues (Zippo Corporation, 2023). Adhering to these steps maintains safety and longevity, aligning with U.S. consumer safety standards.