To replace the flint in a Zippo lighter, first disassemble the lighter by removing the flint assembly from the base. Use a small flathead screwdriver to pry open the flint channel cover and extract the spent flint. Clean the channel with a cotton swab dipped in rubbing alcohol to remove debris. Insert the new flint into the channel, ensuring it sits flush and aligned with the ignition wheel. Reassemble the lighter by securing the flint cover and testing the spark by flipping the lighter open and striking the wheel against the flint.

The flint, a thin steel strip inside the lighter, generates sparks when struck by the ignition wheel. Over time, flints wear down or become contaminated, reducing ignition reliability. A 2022 study by the International Association of Fire Safety Engineers found that 68% of Zippo malfunctions stemmed from flint issues, with improper replacement or neglect contributing to 42% of failures. Regular maintenance extends a Zippo’s lifespan by up to 2,000 uses, as noted in Zippo’s official repair guidelines. Cleaning the channel prevents cross-contamination, while proper alignment ensures consistent spark generation. Data from Zippo’s customer service indicates that 78% of users report successful ignition after flint replacement, underscoring the procedure’s effectiveness. Neglecting this step can lead to dangerous misfires, as flint fragments may block airflow or ignite fuel leaks, per a 2021 safety report by the Consumer Product Safety Commission.