5 Fixes for Sputtering Torch Lighters

A sputtering torch lighter can turn a relaxing cigar session into a frustrating ordeal, leaving your Corona or Churchill with an uneven burn. If you’re asking, why does my torch lighter sputter? You’re likely dealing with a common issue that plagues cigar smokers, from beginners to aficionados. Whether it’s a budget Vertigo or a premium S.T. Dupont, sputtering often stems from simple, fixable problems like air pockets, clogged jets, or low-quality butane. In this 2025 guide, we’ll uncover the top reasons your torch lighter sputters and provide five cigar-specific fixes to restore a steady, clean flame. Plus, we’ll recommend Amazon products to keep your lighter reliable, ensuring every cigar lights perfectly. Ready to fix that sputter and enjoy your smoke? Let’s dive into these solutions tailored for cigar enthusiasts.

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Why Your Torch Lighter Sputters

Sputtering—when your lighter’s flame flickers, pops, or dies out—is a common issue for torch lighters used in cigar smoking. Here are the main culprits, especially relevant for 42-60 ring gauge cigars:

• Air Pockets in the Fuel Tank: Trapped air from improper refilling disrupts fuel flow, causing an unsteady flame.
• Clogged Burner Jets: Residue from low-quality butane or environmental debris blocks the jets, leading to sputtering.
• Low or Impure Butane: Insufficient fuel or impure butane (less than triple-refined) creates inconsistent flames.
• Improper Flame Adjustment: A flame set too high or low can cause popping or flickering.
• Faulty Spark Mechanism: A worn or misaligned igniter may produce a weak spark, failing to sustain the flame.

These issues can ruin the toasting process, tainting cigar flavor or requiring multiple lights, especially in outdoor settings like patios or golf courses. Our fixes below are tailored for cigar smokers, ensuring your lighter performs reliably. For the best fuel to prevent sputtering, check our guide on the best butane fuel for torch lighters.

Best butane fuel for torch lighters

5 Fixes for a Sputtering Torch Lighter

These five cigar-specific solutions will stop your torch lighter from sputtering, restoring a steady flame for perfect cigar lighting. Each includes step-by-step instructions and Amazon products to make fixes easy.

1. Bleed the Air Pockets

Air pockets trapped during refilling are a leading cause of sputtering, disrupting fuel flow in lighters used for cigars.

• How to Fix:
  1. Turn off the lighter and let it cool (5-10 minutes if recently used).
  2. Set the flame adjustment screw to the lowest setting (usually a “-” symbol).
  3. Hold the lighter upside-down and press the fill valve with a small screwdriver or bleed tool until a hissing sound stops (5-10 seconds).
  4. Wipe the valve with a clean cloth and refill with high-purity butane (see Fix 3).
• Cigar Tip: Bleeding ensures a consistent flame for toasting 42-50 ring gauge cigars, preventing flavor taint from uneven burns.
• Product Needed: Bleed tool or small screwdriver (included in lighter kits, ~$5-$20).

Shop Torch Lighter Bleeder Tools on Amazon

2. Clean the Burner Jets

Clogged jets from butane residue or dust can cause sputtering, especially in lighters used frequently for cigars.

• How to Fix:
  1. Ensure the lighter is cool and turned off.
  2. Use a can of compressed air to blow short bursts into the burner jets (flame outlet).
  3. Wipe the burner area with a soft cloth to remove surface debris.
  4. Test the flame; repeat if sputtering persists.
• Cigar Tip: Monthly cleaning prevents sputtering during 48-60 ring gauge cigar sessions, ensuring clean toasting.
• Product Needed: Compressed air can (e.g., Dust-Off, $5-$10).

Shop Compressed Air on Amazon

3. Use High-Purity Butane

Low-quality butane (less than triple-refined) leaves residue, clogging jets and causing sputtering that affects cigar flavor.

• How to Fix:
  1. Bleed the lighter completely (see Fix 1).
  2. Refill upside-down with 5x+ refined butane (e.g., Xikar Purofine) in short bursts (3-5 seconds, 2-3 times).
  3. Wait 2-3 minutes for the butane to settle before igniting.
  4. Test the flame for consistency.
  5. Adjust flame height as necessary
• Cigar Tip: High-purity butane ensures a clean burn for premium cigars, avoiding chemical aftertastes.
• Product Needed: 5x+ refined butane (e.g., Xikar Purofine, $10-$12).

Shop The Best Butane on Amazon

Learn about the Best Torch Lighter Butane Fuel with our simple guide

4. Adjust the Flame Setting

An improperly set flame (too high or low) can cause sputtering or popping, disrupting cigar toasting.

• How to Fix:
  1. Locate the flame adjustment screw (usually on the lighter’s bottom).
  2. Use a screwdriver to set it to a medium position (halfway between “+” and “-”).
  3. Test the flame; adjust slightly up or down for a steady blue flame (~1-2 inches).
  4. Re-test after refilling, as butane pressure can shift settings.
• Cigar Tip: A medium flame is ideal for 42-50 ring gauge cigars, ensuring even toasting without scorching.
• Product Needed: Small screwdriver (included in lighter kits, ~$5-$10).

Shop Screwdriver Kits on Amazon

5. Check the ignighter

A weak or faulty spark mechanism can cause intermittent ignition, leading to sputtering, especially in older lighters.

• How to Fix:
  1. Press the igniter button to check for a firm click and visible spark.
  2. Use compressed air to clear debris around the spark area.
  3. If the spark is weak or absent, contact the manufacturer (e.g., Xikar’s lifetime warranty) or consider a replacement.
  4. Test with high-purity butane after cleaning.
• Cigar Tip: A reliable spark ensures quick lighting for 48-60 ring gauge cigars, even outdoors.
• Product Needed: A reliable replacement lighter (e.g., Vertigo Cyclone, $14-$20).

See our most reliable torch lighters here

Tips to Prevent Sputtering in the Future

These tips will keep your torch lighter from sputtering, ensuring reliable cigar lighting:

• Use 5x+ Refined Butane: Prevents clogs and ensures clean burns. See our best butane fuel guide.
• Bleed Before Refilling: Remove air pockets every time you refill. Check our how to bleed a butane lighter guide.
• Clean Monthly: Use compressed air to clear jets. Explore our how to clean a torch lighter guide.
• Store Properly: Keep lighters in a cool, dry place to maintain valve and jet integrity.

These habits ensure your lighter performs flawlessly for every cigar session, from 42-ring Coronas to 60-ring Churchills. Shop Amazon for butane and tools to keep sputtering at bay.

See our guide on Troubleshooting
Torch Lighters here

FAQs

Why does my torch lighter sputter after refilling?

Sputtering after refilling is often due to air pockets or low-quality butane. Bleed the lighter and use 5x+ refined butane (see Fix 1, 3).

How often should I bleed my lighter to prevent sputtering?

Bleed before every refill or monthly for regular cigar smokers to maintain a steady flame for 42-60 ring gauge cigars.

Can a clogged jet cause my lighter to sputter?

Yes, residue or debris in the jets causes sputtering. Clean with compressed air monthly (see our how to clean a torch lighter guide).

What’s the best butane to stop my lighter from sputtering?

Use 5x+ refined butane (e.g., Xikar Purofine, Vector KGM). Check our best butane fuel guide for top picks.

Should I replace my lighter if it keeps sputtering?

If fixes don’t work, consider a reliable model like Vertigo Cyclone. See our most reliable torch lighters guide.

Most Reliable Torch Lighters
Best Single Jet Torch Lighters

Conclusion To Why Does My Torch Lighter Sputter

A sputtering torch lighter doesn’t have to ruin your cigar experience. By bleeding air, cleaning jets, using high-purity butane, adjusting the flame, or checking the spark, you can restore a steady flame for perfect toasting of 42-60 ring gauge cigars. Our five fixes, tailored for cigar smokers, keep your lighter reliable, whether it’s a budget Vertigo or a premium Xikar. Shop our recommended butane, tools, and lighters on Amazon to prevent sputtering, and share your troubleshooting tips in the comments below!