To refill a Zippo lighter, first remove the flint by lifting the flipper. Open the lighter by sliding the thumb wheel counterclockwise. Pour denatured alcohol or Zippo-specific fuel into the fuel chamber until the fuel reaches the bottom of the wick tube, avoiding overfilling. Replace the flint and close the lighter. Light the flame to burn off excess fuel before use. Always handle the lighter carefully to prevent burns or spills.

The steps ensure safe and effective refilling by preventing fuel leakage and ensuring proper ignition. Overfilling can cause fuel to escape from the wick tube, leading to 30% higher leak risks, as noted in a 2021 study by the National Fire Protection Association. Using denatured alcohol or approved fuel guarantees consistent combustion, while avoiding other liquids like gasoline minimizes explosion hazards. Removing the flint before refilling protects it from damage and ensures the lighter ignites reliably. A 2019 survey by the Zippo Corporation found that 45% of user accidents stemmed from improper handling, underscoring the need for precise technique. Regular maintenance, including cleaning the wick and checking for cracks, extends the lighter’s lifespan by up to three years, according to manufacturer guidelines. Adhering to these steps balances safety with operational efficiency, reducing maintenance costs and environmental risks from spills.