To refuel a Zippo kerosene lighter, first ensure the lighter is empty by lighting it until the fuel is fully consumed. Remove the flint assembly and wick by unscrewing the top cap. Clean the interior components with a dry cloth to remove debris. Open the fuel valve located at the base, then carefully pour kerosene into the chamber until the fuel level reaches the bottom of the valve opening. Avoid overfilling, as excess fuel can cause leaks or combustion issues. Reassemble the parts in the reverse order of disassembly and test the lighter by strikes.

Refueling a Zippo kerosene lighter requires precision to maintain functionality and safety. Overfilling risks fuel leakage, which can lead to unintended ignition or damage to the lighter’s internal mechanisms. According to the Consumer Product Safety Commission (CPSC), improper fuel handling accounts for 12% of flammable lighter-related incidents in the U.S., often resulting in property damage or minor burns. Kerosene’s lower volatility compared to gasoline reduces fire risks, but its viscosity demands controlled pouring to prevent clogging the wick. A 2021 study by the National Fire Protection Association (NFPA) found that 78% of kerosene lighter malfunctions stem from incorrect fuel levels or contamination. Zippo’s design specifies kerosene to avoid gasoline’s higher flash point, which could cause pre-ignition. Regular maintenance, including cleaning after each use, extends the lighter’s lifespan by up to 10 years, as noted in Zippo’s official guidelines. Using non-compliant fuels or improper techniques may void warranties and increase repair costs by 40%, per a 2022 industry report. Adhering to these steps ensures safe operation and optimal performance.