How to Refill a Zorro Butane Lighter (Safely)

A quick, safety-first guide to refilling Zorro jet/butane lighters. Use high-quality, filtered butane and follow these steps to keep your lighter reliable.

What you’ll need

• Zorro butane lighter

• High-quality filtered butane (multiple nozzle adapters)

• Small tool/paper clip (to bleed air)

• Soft cloth or paper towel

Safety checklist

Work in a ventilated area, away from heat/flames. Do not smoke while refilling. Wear eye protection if available. Keep fuel away from children and pets.

Step 1: Set flame to LOW and lock the ignition

Turn the flame adjuster to minimum. If your model has a lock, engage it to prevent accidental ignition.

Step 2: Bleed the tank completely

Turn the lighter upside down. Use a small tool to press the refill valve until all hiss stops—this purges trapped air/old fuel that causes sputtering.

Step 3: Fit the correct nozzle and invert the can

Choose the adapter that seals firmly on the valve. Hold the lighter upside down, invert the butane can, and press straight down.

Step 4: Fill in short bursts

Charge for 5–10 seconds, release, then repeat once if needed. Stop if fuel splashes or leaks—overfilling reduces performance.

Step 5: Rest 3–5 minutes

Let the lighter warm to room temperature so pressure stabilizes. Wipe any residue, then set the flame to medium.

Step 6: Test and fine-tune

Ignite and adjust the flame height. If the flame is weak, bleed and add a small top-off. If it flares or leaks, stop and allow vapors to dissipate.

Pro tips: Use 5x+ filtered butane, store the can upright, and refill before the tank is bone-dry to reduce air intake.