Quick answer: To refill a Zippo lighter, pull the insert out of the case, turn it upside down and lift the corner of the felt pad. Slowly squeeze lighter fluid into the cotton packing and stop when the fluid reaches the top of the packing. Wipe the insert and your hands dry, close the fluid can, slide the insert back into the case and only then strike it. Those are the same steps as Zippo’s official fill instructions.

The whole job takes under a minute. What goes wrong is nearly always overfilling, lighting a wet lighter, or putting butane where fluid belongs. The steps below avoid all three.

What You Need

• Lighter fluid. Zippo recommends its own fluid, and a 4 oz can of Zippo fluid lasts a regular user a long time. Never use butane in a classic fluid insert.
• A paper towel for spills.
• A paper clip (optional) if the felt pad is hard to lift.

How to Refill a Zippo Lighter, Step by Step

1. Work away from flames. Let the lighter cool and make sure it’s out. Fill somewhere ventilated, away from candles, stoves and cigarettes.
2. Remove the insert. Hold the case in one hand, open the lid and pull the insert straight up out of the case with the other.
3. Turn it over and lift the felt pad. On the bottom you’ll see a felt pad marked “Lift to fill”. Peel back one corner to expose the cotton packing. An unfolded paper clip helps if it’s stuck. Don’t take the flint spring screw out.
4. Fill slowly. Squeeze the fluid into the cotton in a thin stream, moving around so it soaks in evenly.
5. Stop at the top of the packing. Zippo says to stop when the fluid reaches the top of the packing material, or when the cotton starts to change color. A Zippo holds the fluid in the cotton, not in a tank, so anything extra just leaks out.
6. Close the can and wipe everything dry. Put the cap back on the fluid, then wipe the insert, the case and your hands. If you spilled any, give it a minute or two to evaporate.
7. Put the insert back and light it. Push the insert fully into the case and strike the wheel downward with your thumb. Close the lid to put the flame out, because a Zippo doesn’t go out on its own.

Filling an old Zippo? A vintage lighter fills exactly the same way. If it hasn’t been used for years, the cotton may be packed down or the wick may be dry and charred. A fresh wick and a full fill usually bring it back. If parts are broken, the lifetime guarantee covers repairs to the case and insert.

Safety: Don’t Overfill, Wipe It, Let It Dry

• Don’t overfill. Overfilling is the most common mistake. Excess fluid seeps out around the insert and onto your hand or pocket. Zippo says that if there’s fuel on the outside, don’t put it in your pocket or near your skin.
• Wipe off spills. Lighter fluid on the case or your fingers catches fire with the wick. Our can a Zippo explode? guide explains why spills, not explosions, are the real risk.
• Let it dry before lighting. Close the can and make sure no spilled fuel is nearby before you strike it.
• Wash it off your skin. Lighter fluid irritates skin. If you get some on you, wash it off right away.
• Carry it bottom down. Zippo suggests keeping a lighter bottom down in your pocket to cut down on leaks.

How Long Does a Zippo Fill Last?

With regular daily use, expect roughly one to two weeks per fill, and less if you light it often. The bigger factor is evaporation: Zippo fluid is a petroleum distillate, so it evaporates even when you don’t use the lighter. A Zippo isn’t sealed like a butane lighter. The lid closes over the chimney, but the vapor still slowly escapes.

To make a fill last longer:

• Keep the lid shut whenever you aren’t using it.
• Keep it out of sunlight and away from heat such as a car dashboard or a radiator.
• Make sure the flint spring screw is fully tightened so the lid closes properly. Zippo notes that a tight seal helps slow evaporation.
• Top it up before a trip rather than counting on last week’s fill.

If evaporation bothers you, the butane insert below is the fix. Our Zippo vs BIC vs arc lighter comparison looks at the running costs of each.

Refilling a Zippo With Butane (Butane Inserts Only)

You can only put butane in a Zippo that has a butane insert. Those inserts have a fill valve on the bottom and work like any refillable butane lighter. Zippo’s instructions are to hold the insert upside down, fill for 5–6 seconds, briefly press the valve to release trapped air, fill again and wait at least two minutes before lighting. The full routine is in our butane lighter refill guide.

A classic insert has no valve or sealed tank, so butane just boils off. If you want a butane flame in your Zippo case, read butane vs lighter fluid: which Zippo insert to buy first.

Zippo Fluid vs Ronsonol

Both are naphtha-type lighter fluids, and both will light a Zippo. Zippo designs its lighters around its own fluid and says it burns cleanly and lights quickly, and its current formula is lower in odor and less irritating to skin. Many users notice less of a fuel smell with Zippo fluid. Ronsonol is easy to find and works fine in an emergency. Whichever you use, stick to one fluid made for wick lighters. Never use gasoline, alcohol or other fuels.

Replacing the Flint and Wick

A full tank doesn’t help if the spark or the wick is worn. Both are cheap, five-minute jobs, and Zippo’s flint and wick pack covers years of both.

Flint. Zippo says an average user needs a new flint every few weeks. Take the insert out, turn it over and unscrew the flint spring with a coin or a small screwdriver (it’s under tension). Tap out what’s left of the old flint, drop in a new one, then screw the spring back in as far as it will go. If the wheel binds, turn it backwards a few times. You can store a spare flint under the felt pad.

Wick. When the tip turns black, pull the wick up with tweezers and trim it level with the chimney. Zippo says to replace the wick after two or three trims, or when the lighter needs several strikes to catch. To replace it, take out the felt pad and cotton, thread the new wick down through the chimney and pack the cotton back in small pieces with the wick weaving through it in an S shape. Then trim it level with the chimney.

More detail, including what Zippo repairs for free, is in our Zippo repair and care guide.

Troubleshooting

FAQ

How do you refill a Zippo lighter? Pull the insert out of the case, turn it over and lift the felt pad. Slowly soak the cotton with lighter fluid until the fluid reaches the top of the packing, then wipe the lighter and your hands dry, close the can and put the insert back before lighting it.

How much fluid do you put in a Zippo? Just enough to saturate the cotton. Stop when the fluid reaches the top of the packing or the cotton changes color. More than that leaks out.

What happens if you overfill a Zippo? The extra fluid seeps out onto the case and your hands, and it can catch fire along the outside when you strike it. Wipe it off and let it evaporate before you light it.

How long should you wait after filling a Zippo? There’s no fixed wait like with butane. Once the can is closed and the lighter and your hands are wiped dry, you can light it. If you spilled any, give it a minute or two to evaporate first.

Why does my Zippo run out of fluid so fast? Lighter fluid evaporates even when you aren’t using the lighter. Keep the lid closed, keep it away from heat and sunlight, and make sure the flint spring screw is tight.

Can I put butane in my Zippo? Only if it has a Zippo butane insert. A classic fluid insert has no valve, so the butane escapes straight away. Use lighter fluid in a fluid insert.

Is Ronsonol OK for a Zippo? Yes, it works. Zippo recommends its own fluid, and many users find it smells less, but Ronsonol will light the lighter.

How do you fill an old Zippo lighter? The same way as a new one. If it’s been sitting for years, replace the wick and flint too, and if anything is broken, Zippo’s lifetime guarantee covers the repair.

How often do you change a Zippo flint? Every few weeks for an average user, or whenever the spark gets weak. Zippo flints are sold in small cards, and you can keep a spare under the felt pad.

When should you replace a Zippo wick? After two or three trims, or when the lighter takes several strikes to light. Each wick is almost four inches long.

Is a Zippo a good gift? It’s one of the few gifts that can last a lifetime, especially with a can of fluid and spare flints. See our Zippo gift guide for picks.