I have followed the instructions below that came with my XIKAR ligher, with the exception of releasing the pressure before filling with a small screwdriver, insted of a XIKAR MTX Multitool. I have never had a problem filling my lighter. Maybe step one and two are the secret?
Re-filling and adjusting your lighter is much easier with a XIKAR MTX Multitool!
Filling and re-filling lighters:
Lighter contains inflammable gas under pressure. Handle
Ensure that flame is extinguished before attempting to fill.
Never attempt to ignite lighter while refilling.
Read butane canister warning labels.
Only refill lighter in a well-ventilated area.
Hold lighter away from face and clothing while filling lighter.
Never fill lighter around any heat source, sparks or flame.
Triple refined premium butane is highly recommended, as
lower quality butane has been known to clog lighters.
Release all tank pressure by pressing on inlet valve with a
small screwdriver or XIKAR MTX Cigar Multi Tool bleeder.
KEEP OUT OF REACH FROM CHILDREN.
1) Set flame adjustment to lowest setting (-).
2) Hold lighter in upside down position and insert butane tank tip directly
on the fuel. Press down firmly for about 10 seconds.
3) Before igniting lighter, wait 2-4 minutes. This will allow for excess
butane to evaporate and butane gas to reach room temperature.
4) Turn flame adjuster to lower setting and increase flame to desired height.