1. Introduction
This manual provides essential information for the safe and effective use of your Zippo Butane Lighter Insert - Yellow Flame. This insert is designed to fit any Classic Zippo lighter case, offering a reliable yellow flame with butane fuel. Please read these instructions carefully before use and retain them for future reference.
Image 1: Zippo Butane Lighter Insert - Yellow Flame, shown in its polished chrome finish.
2. Safety Information
WARNING: KEEP OUT OF REACH OF CHILDREN.
Ignite away from face and clothing. Be sure flame is out after use. Contains flammable gas under pressure. Do not keep lit for more than 30 seconds. This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
Image 2: Close-up of the Zippo Butane Lighter Insert showing safety warnings.
3. Product Features
- Genuine Zippo Yellow Flame Insert with reliable flint wheel ignition.
- Produces a pressurized single flame up to 1,400°F/760°C.
- Refillable with Zippo premium butane fuel (sold separately).
- Fuel capacity: 0.9g.
- Designed to fit all Classic Zippo lighter cases. Does not fit Slim or 1935 Replica cases.
- Retains the famous Zippo "click" sound.
- Made in China to Zippo quality standards.
4. Setup
4.1. Installation into a Zippo Case
- Open your Classic Zippo lighter case.
- Remove the existing insert from the case.
- Insert the Zippo Butane Lighter Insert into the Zippo case. Ensure it fits snugly.
- Close the lighter case.
4.2. Filling with Butane Fuel
The Zippo Butane Lighter Insert is shipped unfilled. For optimal performance, use Zippo premium butane fuel.
- Remove the insert from the Zippo case.
- Locate the refill valve on the bottom of the insert (refer to Image 3).
- Hold the insert upside down.
- Press the nozzle of the butane fuel can firmly into the refill valve.
- Hold for approximately 5-10 seconds, or until the insert begins to frost, indicating it is full.
- Wait a few seconds for the fuel to stabilize before attempting to ignite.
Image 3: The bottom of the Zippo Butane Lighter Insert, highlighting the butane refill port and flame adjustment screw.
Important: Before refilling, it is recommended to purge any residual air from the insert. To do this, use a small tool (like a pen tip) to press down on the refill valve until no more gas is audibly escaping.
5. Operating Instructions
5.1. Ignition
- Open the Zippo lighter case.
- Press the ignition button (flint wheel mechanism) to ignite the yellow flame.
- Release the button to extinguish the flame.
Image 4: A hand demonstrating the ignition of the Zippo Butane Lighter Insert, showing the yellow flame.
5.2. Flame Adjustment
The flame height can be adjusted using the screw located on the bottom of the insert (refer to Image 3).
- Use a small flathead screwdriver or similar tool.
- Turn the screw towards the '+' symbol for a larger flame or towards the '-' symbol for a smaller flame.
6. Maintenance
- Regularly check the fuel level and refill as needed.
- Keep the insert clean and free from debris to ensure proper operation.
- Store in a cool, dry place away from direct sunlight and heat.
7. Troubleshooting
7.1. Lighter Fails to Ignite or Flame is Weak
- Low Fuel: Check the butane level and refill if necessary (refer to Section 4.2).
- Air in Tank: Purge any air from the fuel tank before refilling (refer to Section 4.2).
- Flame Adjustment: Ensure the flame adjustment is not set too low (refer to Section 5.2).
- Worn Flint: Replace the flint if it is worn down and not producing a spark.
7.2. Flame is Too Large or Unstable
- Flame Adjustment: Adjust the flame height to a lower setting (refer to Section 5.2).
8. Specifications
| Brand | Zippo |
| Model Number | 65800 |
| Color | Yellow Flame |
| Material | Zinc |
| Style | Butane |
| Item Weight | 1.6 ounces |
| Fuel Type | Liquefied Petroleum Gas |
| Product Dimensions | 2"L x 1.4"W x 0.5"Th |
| UPC | 191693658002 |
| Manufacturer | Zippo Manufacturing Company |
| Included Components | Unfilled lighter insert, instruction manual |
9. Warranty and Support
This Zippo Butane Lighter Insert comes with a 2-year warranty. For warranty claims or further support, please contact Zippo Manufacturing Company directly.
Visit the Zippo Store for more information and products.
10. Product Overview Video
Watch this official video from Zippo Manufacturing Company for a visual overview of Zippo Lighter Inserts, including the Yellow Flame Butane option.
Video 1: Official Zippo Lighter Inserts overview, demonstrating various insert types and their features.
