Refilling Lighter Fluid: A Step-By-Step Guide To Replenishing Fuel

Lighter fluid is a quick and convenient way to get your coals ready for grilling. However, it is not the only option. If you're out of lighter fluid or want to avoid adding chemicals to your coals, there are several alternatives to choose from. Some popular methods include using a chimney starter, an electric starter, or even plain old newspaper. For those seeking a more natural taste without the chemical residue, these alternatives are worth exploring. Additionally, refilling a disposable lighter with a new reservoir of lighter fluid is also an option to consider.

Refilling a disposable lighter

• Prepare your work area: Choose a well-ventilated area, away from any flames or sparks. Cover your work surface with something like newspaper or a drop cloth to prevent fuel from coming into contact with the surface.
• Open the refill valve: Turn the lighter upside down and locate the small hole at the bottom. Insert a push pin into the hole and flip the lighter so that the pin is resting on the work surface. Press down on the lighter firmly until you 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 removed to open the valve.
• Verify the valve is open: With the push pin still inserted, shake the lighter. You should hear the beebee rattling around inside, confirming that the seal has been removed.
• Purge the remaining air and fuel: Point the lighter away from your face and remove the push pin. You should hear a puff of air as the pin is removed. If you hear a hissing sound, there is still fuel inside the lighter, and you should stop and allow it to empty completely before proceeding.
• Prepare your butane applicator: The butane applicator may not fit perfectly into the lighter's refill valve, which can cause gas to leak. To prevent this, take three rubber grommets (small circular rubber pieces with a hole in the middle) and slip them onto the applicator so that the rubber of the final grommet extends just slightly beyond the tip.
• Refill the lighter: Turn the lighter upside down so that its bottom faces upwards. Insert the grommet-covered tip of the applicator into the refill valve and press down on the bottle to release the butane. Hold it in this position for about five seconds to allow the lighter to fill completely.
• Seal the refill valve: Remove the applicator from the valve and quickly seal the valve with your thumb. Pick up the push pin with your free hand and quickly insert it back into the hole to plug the hole. You may hear some hissing, so hold your thumb firmly to minimise fuel escape.
• Optional: Remove the end of the push pin: If the push pin has a contoured plastic end, it may get caught on things and pull out. To avoid this, you can cut the plastic end off with clippers and file down any jagged edges with a metal file.

Refilling a Zippo lighter

Step 1: Remove the inside unit from the case

Gently pull the lighter insert out of its case by gripping the chimney or flint wheel. You can use a piece of wire through a hole in the chimney if it's stuck. Be careful not to crush the flint wheel or chimney when pulling.

Step 2: Lift the felt pad

Turn the lighter over and lift the felt pad with a screwdriver or paperclip. The bottom of the unit has a small hole in the middle and the words "Lift to Fuel". You can also use the nozzle of Zippo lighter fluid to open the felt pad.

Step 3: Saturate the packing material with lighter fluid

Pour lighter fluid onto the cotton for about five seconds and let it soak in. Keep filling until the top of the cotton is fully saturated and slightly darker in colour. Stop filling when the fluid reaches the top of the packing material or changes colour. Do not overfill as this will cause leaking.

Step 4: Reinsert the inside unit

Close the felt pad and place the unit back inside the case. Push down on the unit to completely insert it and apply gentle pressure until it's secure. Wipe away any excess fluid from the lighter and your hands before igniting.

Step 5: Test the lighter

Wait 1-2 minutes for the lighter to absorb the fluid. Then, strike the flint wheel to light the Zippo. If it doesn't light after three tries, add more lighter fluid.

Tips:

• Always use high-quality lighter fluid to protect your Zippo. Methylated spirits and F-gasoline can damage it.
• Refill your Zippo over a sink to avoid spills on finished surfaces.
• Avoid getting lighter fluid on your skin. If contact occurs, wash the area with mild soap and water.
• Keep the lid closed when not in use to prevent fluid evaporation.

Refilling a wand or extended-reach lighter

Steps to Refill a Wand or Extended-Reach Lighter:

Release the remaining gas from the lighter. Use the smallest nozzle, a pin, or a screwdriver to press down on the small hole at the bottom of the lighter until you no longer feel any pressure or hear any sound. This step is crucial to ensure that the lighter is empty before refilling.

Prepare the butane can. Shake the can to ensure the fluid is mixed well, especially if it is an older can. Ensure the can has a nozzle that fits the refill valve of your lighter. If not, use a nozzle adapter to ensure a secure fit.

Position the lighter and butane can. Place the lighter upside down on a solid surface with the refill valve facing upwards. Hold the butane can upside down with the nozzle inserted into the refill valve of the lighter.

Refill the lighter. Press down on the butane can to release the fuel into the lighter. Keep pressing for about five seconds or until the lighter is full. You may feel some butane leak over your fingers, so consider wearing gloves.

Seal the refill valve. Once the lighter is full, remove the butane nozzle and quickly seal the valve with your thumb. Be careful as some fuel may escape. You can use a push pin to plug the hole if necessary.

Clean up. Wipe down any areas exposed to fuel with a damp cloth, including your hands and work surfaces. Ensure there are no fuel leaks before testing the lighter.

Test the lighter. After allowing the butane to settle for a few minutes, ignite the lighter in a well-ventilated area. Ensure the flame is adjusted to the desired height.

Tips for Refilling Wand or Extended-Reach Lighters:

• Always use high-quality butane fuel from reputable brands to avoid impurities that can clog your lighter.
• Ensure the lighter is empty before refilling to avoid fuel spray and leakage.
• Work in a well-ventilated area when refilling your lighter to prevent the buildup of harmful fumes.
• Protect your work surface with a cover, such as newspaper or a drop cloth, to catch any fuel spills.
• If your lighter is not lighting properly, try cleaning the head of the lighter with a brush or a long needle to remove any built-up residue.

Replacing the flint on a butane lighter

Step 1: Check if the lighter needs a new flint

If your lighter is not sparking properly, it may be missing flint. Check this first before replacing it.

Step 2: Open the lighter

Remove the insert from the lighter case by pulling on the insert by the flame guard, the raised part of the insert with holes in it.

Step 3: Remove the screw

Unfasten the screw at the bottom of the insert, which is holding the flint spring in place, by turning it counter-clockwise with a screwdriver. Pull out the screw and attached flint spring.

Step 4: Remove the old flint

Turn the insert upside down and gently tap the insert into your palm to knock the flint out. The flint will be a very small cylinder, around the size of the flint spring tip.

Step 5: Insert the new flint

With the bottom of the insert still facing upwards, drop the new flint into the flint hole.

Step 6: Reassemble the flint mechanism

Reinsert the spring into the hole and screw the mechanism back in place.

Step 7: Test the new flint

Replace the insert back into the lighter case and close the case. Try lighting the lighter as you would normally. If the lighter still does not work, it may be out of fuel.

Replacing the flint on a Zippo lighter

If your Zippo lighter isn't creating sparks, the likely cause is a worn-out flint. The flint is a small stick that strikes the wheel when it is turned, creating sparks that light the wick. If the flint is not visible or unable to touch the wheel, it needs to be replaced. Flints typically need to be replaced every few weeks for an average user.

To replace the flint in your Zippo lighter, follow these steps:

• Remove the inside unit (insert) from the case: Open the lid of the lighter and pull the lighter out of its metal case.
• Unscrew the flint spring: Turn the inside unit over and locate the small screw holding the flint spring in place. Use a small screwdriver or a coin to carefully unscrew it. Slowly remove the spring, being careful as it is under tension and may fly away.
• Remove any remaining flint: Turn the inside unit right-side up again and gently tap it on a hard surface to dislodge any remaining flint. You can use an unfolded paperclip to remove any stubborn flint slivers or residue.
• Insert a new flint: Place a new flint into the brass-colored flint tube. Ensure you do not confuse the brass tip on the end of the flint spring with the flint, as it is not a flint.
• Replace the flint spring: Reinsert the flint spring and turn it clockwise until tight. Make sure the screw is tightened sufficiently so that the lid can fully close. A tight seal will help prevent the lighter fluid from evaporating.
• Test the lighter: Reinsert the inside unit into the case and ensure it is seated correctly by closing the case. Test the lighter by turning the wheel as you would normally. If the flint wheel binds, turn the wheel backward a few times.

You can store extra flints under the felt pad for future use.

Frequently asked questions