You should feel and hear a small “pop” as the pin pushes a metal beebee out of place. This beebee seals the release valve and must be pushed out of the way. To verify the beebee seal has been removed, with the push pin still inserted, shake the lighter. You should be able to hear the beebee rattle around. [2] X Research source
Attempting to purge a lighter that has fuel remaining inside will cause fuel to be sprayed out of the refill valve. To prevent fuel from getting on your work surface, lay down a cover, like newspaper or a drop cloth. Wipe down any areas exposed to fuel with a water dampened rag. Also, your hands may have gotten fuel on them. Wash them with soapy water.
The rubber of the final grommet should extend just slightly beyond the tip of the butane spray applicator. Circular rubber grommets can be purchased at your local hardware store in variety packs in the hardware section. [4] X Research source
Because of the seal formed by the rubber grommets, you shouldn’t hear any noise as the lighter refills. The lighter should refill completely in about five seconds. When finished, release pressure on the refill bottle but keep the applicator inserted in the refill valve. [6] X Research source
You may hear some hissing when your thumb is plugging the refill valve. Hold your thumb firmly to reduce the escape of fuel. This part of refilling a disposable lighter can be difficult at first. Move quickly to prevent freshly replenished fuel from escaping. [7] X Research source
The screws on these types of lighters tend to be very small, so a regular-sized screwdriver may be too big. Try a mini screwdriver instead. If you can’t get any mini screwdrivers, pick up a repair kit for glasses. They usually contain a mini screw driver that may work.
If you can’t get a flat head screwdriver, try a butter knife instead. You need something thin that you can wedge into the seam and pry it apart.
The fuel reservoir looks very similar to a standard disposable lighter. Place the reservoir and a fresh disposable lighter side by side in front of you. The empty long-stemmed lighter can be set off to the side. This part won’t be needed until you put the lighter back together.
After these parts have been removed, keep the disassembled lighter positioned upright to prevent it from spilling fuel. [11] X Research source
The jet and the spring should fall into place easily. Press the button-insert into place with moderate force. You should feel it snap into place.
If the lighter does not ignite, it’s likely the reservoir button-insert, spring, and/or jet were not correctly installed. The reservoir should slot into place in a small, internal cavity inside the handle of the long-stemmed lighter. [12] X Research source
Verify the butane works with your lighter by reading its label instructions. Always follow the safety directions on the canister to achieve the best results. Select a high-quality butane specifically intended for butane lighters. Low-quality fuel may not light as well.
Your kitchen or an outside area are good places to refill your butane lighter because both are open spaces. Open a window or turn on a vent in the room if it is available. If airflow is still poor even with a window open, use a stationary fan to improve circulation. Remaining fluid or gas may spray onto your work surface while refilling. Protect your work surface with a layer of newspaper or a drop cloth. [13] X Research source
The refill lever is also sometimes known as the nipple. It is located on the bottom of most butane lighters and usually looks like a small hole with a tiny, circular valve inside. If you don’t have a screwdriver, use a pen, paperclip, or similar tool to push down the valve and release remaining air in the lighter. If lighter fluid sprays onto your hands or tools, rinse these thoroughly in soap and water. If you forget to do so, the fuel may ignite and burn you when you test the lighter.
By turning the adjuster to its lowest setting, even if you accidentally ignite the lighter, the flame will be small and unlikely to do harm or damage. Some lighters may indicate the minimum setting direction with a minus sign ( - ). Turn the adjuster screw towards the minus sign to lower the flame. [16] X Research source
While shaking the can, you’ll also be able to feel fluid swish around inside it. This will give you a chance to gauge how much is in the bottle. Nearly empty bottles may not have enough fluid to fully refill your lighter and should be swapped out for a new can of replacement fuel. [17] X Research source
Most butane refill bottles come with an adapter, so before you try to refill, make sure the standard tip fits over the valve. Don’t fill the lighter at an angle. This will let air into the lighter tank. Air in the lighter will cause the lighter to not work properly. It will have to be drained and refilled. [18] X Research source
After filling, if you feel like your lighter isn’t full, repeat this procedure for another five seconds. Refill cans low on fuel may take more time to refuel lighters. Some lighters have a fuel level that you can check. Check the butane level viewer if you have one to gauge the lighter’s fullness. Lighters that are filled up too much will overflow. This can be dangerous, as butane can leak and catch fire when lighting.
Once you’ve refilled and set your flame height, give your lighter a minute or so to absorb the butane. As you wait for butane to be absorbed, check your lighter for leaks. Wipe up leaked fuel with a dampened rag. Rinse the rag frequently. If your lighter leaks, you may have to purge the fuel and refill it again. Check for obvious culprits first, like loose fasteners, before purging and refilling. [20] X Research source
In most butane lighters, butane won’t dissolve over time. Always test your lighter before refilling it to make sure that it is empty.
If you use a different brand of lighter fluid, make sure it is a premium brand. Sub-par fuel may fail to ignite in your lighter. Never use charcoal lighter fluid. Charcoal lighter fluid is not made for a small container like a Zippo. Using charcoal fluid can be very dangerous.
Grab the chimney cap, the small rectangular portion with holes in it, and pull the lighter out. In some cases, you may need to loosen the insert by wiggling it back and forth. The refill access for Zippo lighter’s (and most similarly designed lighters, too) is at the bottom of the insert.
The rectangular felt pad will say “LIFT TO FILL” on it. Lift the felt pad from this end to reveal the rayon balls, which look like cotton, and a wick underneath. There may also be a small hole in the center of the felt pad. Use a small screwdriver or pen and insert it into the hole. Use your tool as a lever to pull the felt pad up.
Be careful not to let lighter fluid drip down the outside of your Zippo or get any on your hands. Wipe up spills with a wet rag. Rinse the rag regularly while doing so to flush fuel down the drain. Refill slowly so you don’t overfill the lighter. If you add too much fluid, your lighter will leak, which can be dangerous.
It’s also a good idea to wash your hands before placing your lighter back into the casing. Some fluid might’ve transferred to your hands without you noticing.
The first couple of times you light your Zippo after refilling, your flame may be bigger than usual. This is completely normal.
Open the lighter. Remove the insert from the lighter case by pulling on the insert by the flame guard, which is the raised part of the insert with holes in it. Remove the flat head slotted screw fastening the flint spring at the bottom of the insert by turning it counterclockwise with a screwdriver. Pull out the screw and attached flint spring. Tap the top of the lighter to knock the flint loose. Replace the flint, spring, and refasten the screw. Your flint wheel should be unstuck. [26] X Research source
The flint will look like a very small cylinder roughly the size of the flint spring tip. Old flints can be thrown away. [27] X Research source
If, after replacing the flint, your lighter still doesn’t work, it might be out of fuel. Check and refill fuel as necessary.
