The EXOTAC titanLIGHT has been an instant winner here at Option Gray. It’s a durable, waterproof, refillable lighter. When you are cold, wet, and need to make a fire, it’s an easy way to get warm and dry quick.
But if you just refilled yours and now you’re seeing an oversized flame, including flames coming out of the vents on the flame guard, you’re in the right place. I ran into this exact problem with my personal titanLIGHT. From the handful of conversations with other customers who experienced the same thing, I know I’m not alone.
When it happened to me, I called EXOTAC directly. Here’s what they told me, and how to fix it.
What’s Actually Happening
The cause is overfilling. When the reservoir takes on too much butane, the excess liquid has nowhere to go. It saturates the wick and the surrounding area inside the flame guard. When you light it, you’re burning off that excess pooled fuel along with what the wick normally feeds. That’s why the flame is oversized and why it spills out of the side vents. As the fuel burns down to a normal level, the flame shrinks back to where it should be.
It’s not a defect. It’s user error. Mine included. And once you know what’s causing it, it’s completely preventable.
How Much Fuel to Use
This is where most people go wrong. You see the reservoir and assume: fill it up. Don’t. A little fuel goes a long way with the titanLIGHT.
According to EXOTAC, you only need about 3mm of fuel. Their recommendation for measuring it without guessing: use the bottom cap of the lighter. Fill the cap twice with butane and pour it into the reservoir. That’s the target amount. It feels like not enough. It is enough. This method keeps you in the right range without getting close to overfill territory.
Already Overfilled? Here’s the Fix
If you’re here because it already happened, good news: there’s an easy way to get rid of the excess without burning it off and damaging your wick.
- Remove both end caps — top and bottom.
- Set the lighter somewhere safe and let the fuel evaporate overnight.
- In the morning, replace the caps and try to light it.
- If it won’t light, too much fuel evaporated. Add one capful of butane and try again.
That’s the whole fix. No drama, no waste. The slow evaporation method brings you back to the right level and the lighter will work normally again.
Other Things Worth Knowing
Overfilling is the most common titanLIGHT problem, but a few other things will keep it running right over the long term.
Wick condition. After heavy use, the wick tip gets charred and crusty. This shows up as weak or inconsistent ignition even when the lighter is fueled. Carefully trim the charred portion with small scissors. A clean wick face lights reliably every time.
O-ring inspection. The waterproof seal depends on the O-rings at both caps. Check them occasionally. If you see cracking or deformation, replace them. EXOTAC sells replacement O-rings, and this is what makes the lighter actually function in wet conditions. Don’t skip it.
Butane quality. Not all butane is the same. Cheaper blends leave more impurities in the wick over time and affect flame quality. Use a refined butane — Colibri or Vector both work well — and the lighter will perform better across its lifespan.
Is It Still Worth Carrying?
Yes. The EXOTAC titanLIGHT is one of the better waterproof lighters you can carry. Machined aluminum, fully refillable, and the waterproofing works. The overfill issue is the only real problem I’ve encountered in regular carry and use, and it’s caused by the user…not the lighter.
Now that you know the cap-twice method, you won’t run into this again. And if you do, the evaporation fix takes care of it without any drama.
Have you run into other titanLIGHT issues? Drop them in the comments below. If there’s a common problem I haven’t covered, I’ll add it to the post.