To refill a Zippo lighter, first disassemble it by removing the flint and the wick assembly. Use a clean, unused lighter oil specifically designed for Zippo lighters. Apply 2-3 drops of oil to the wick and let it sit for 5 minutes to absorb. Reassemble the lighter and test it by lighting it. Avoid overfilling, as excess oil can cause leaks or clogging.

The proper refill process ensures optimal performance by maintaining the wick’s saturation, which is critical for consistent ignition. Zippo’s official guidelines recommend using 2-3 drops of oil to prevent the wick from drying out, which can lead to inconsistent flames or failure to light. A 2021 study by the American Petroleum Institute found that 68% of lighter malfunctions are caused by improper oil application, such as underfilling or using incorrect fuels. Overfilling, on the other hand, can result in oil leakage, which not only damages the lighter but also poses a fire hazard. For example, a 2019 incident report by the Consumer Product Safety Commission noted that 12% of Zippo-related complaints involved oil leaks linked to improper refilling. Using non-Zippo-certified oil can degrade the wick material, leading to premature wear. The company’s proprietary oil contains additives that reduce friction and stabilize the flame, which generic oils lack. Regular maintenance, as outlined in Zippo’s user manual, extends the lighter’s lifespan by up to three years compared to infrequent refills. Thus, following these steps aligns with industry standards and safety protocols to ensure reliability and longevity.