This might be a dumb question but did you try filling the lighter when it was upside down?

I ask because I finally got around to buying a butane lighter the other week, misread the instructions and tried re-filling it while keeping it upright.

It just wouldn't work so I got pissed off and bought an even more expensive one. Same problem again, so... I re-read the instructions, filled it upside down (as they said to), and they both work perfectly now .

Anyway, learn from my stupidity. Of course, if this isn't whats causing your problem, I've just let everyone know how much of a dufus I've been .

Cheers
Rich