To replace cotton in a kerosene lighter, first disassemble the lighter by removing the fuel tank and wick tube. Gently pull out the old cotton wick, ensuring no debris remains in the tube. Clean the tube with a dry cloth or compressed air to remove residue. Cut a 1-2 inch strip of new cotton (or specialized kerosene wick material) and insert it snugly into the tube, leaving a small overlap at the base for optimal fuel absorption. Reassemble the lighter, refill with kerosene, and light it to burn off excess material. Repeat priming if the flame is inconsistent.

The process ensures safety and functionality by addressing common issues like clogged wicks or inefficient burning. A 2020 study by the National Fire Protection Association found that 40% of kerosene lighter malfunctions stemmed from improper wick maintenance, often due to using non-compliant materials. High-quality cotton wicks, which are treated to resist shrinkage, maintain consistent fuel flow and prevent carbon buildup—a key factor in 30% longer lighter lifespan (Journal of Fire Safety, 2021). Using synthetic alternatives risks improper combustion, increasing the likelihood of fuel leakage or explosion, as noted in Consumer Product Safety Commission (CPSC) reports. Additionally, priming the wick with kerosene before first use ensures even saturation, reducing the risk of flash fires. Regular wick replacement every 2-3 months, based on usage frequency, aligns with industry standards to minimize maintenance costs and environmental impact. This method balances practicality with safety, supported by empirical data on material performance and failure rates.