Poulan Pro 655BP Gas Cap (Replacement Options)
For a Poulan Pro 655BP backpack blower, choose a fuel cap only after matching the machine’s full model and serial identification to its illustrated parts list. The safest choice is the listed original-equipment cap assembly. An aftermarket cap is a reasonable option only when fit, seal, and vent details are confirmed. Never force a near-match or run the blower with a leak.
A gas cap can look like a simple, interchangeable part. In practice, a small difference in thread shape, sealing surface, gasket, or vent design can make a replacement unsafe or unusable. The useful question is not “Does this cap look right?” It is “Does this cap match my exact blower?”
I treat the model name as a starting point, not a part number. “655BP” by itself may not identify the correct cap for every product or serial variant. Before ordering, use the product and serial information on your machine and the matching illustrated parts list, or ask a Poulan/Husqvarna parts dealer to confirm the fit.
Equipment setup & safety prep
A compatible replacement must match the exact 655BP identification and the fuel tank’s cap design. Check the correct illustrated parts list before buying, then compare the cap’s threads, sealing surface, gasket, and vent or tether features. A similar-looking cap is not proof of compatibility.
How to identify the right cap
Find the product and serial information on the blower’s identification label. Label locations can vary, so check the machine and its operator’s manual. Record the information as printed; do not rely on a retailer’s short product title or a seller’s guess based only on “655BP.”
Next, find the illustrated parts list (IPL) for that identification. An IPL is a diagram and parts reference that shows how the machine is assembled and which parts are listed for it. Check the fuel cap entry and any notes about product or serial variants. If the correct IPL is not available, ask a Poulan/Husqvarna parts dealer to look it up using the machine’s full identification.
I would not provide a part number from “655BP” alone. Without the matching parts record, naming a specific number could steer you to the wrong cap. Do not assume a cap for another Poulan blower, a chainsaw, or a different 655BP listing will fit.
OEM or aftermarket: what to compare
An OEM cap assembly is the preferred choice when the parts list confirms it for your machine. “OEM” means made or supplied as the original equipment part. An aftermarket cap may work, but its listing should explicitly cross-reference your exact product or serial variant, not just a similar brand or engine size.
| Option | Choose it when | Check before purchase |
|---|---|---|
| OEM cap assembly | The IPL lists it for your blower | Confirm the model/serial match and what parts are included |
| Aftermarket cap | The listing explicitly fits your identified 655BP variant | Confirm threads, gasket, sealing surface, and vent or tether arrangement |
| Used cap | You can verify its part identity and condition | Inspect threads, seal, cracks, swelling, and fit; a used cap may hide wear |
| “Universal” or look-alike cap | Usually avoid unless the seller documents exact compatibility | Appearance alone does not confirm a safe seal or correct venting |
A cap’s vent matters. Some designs include a vent feature; the replacement must preserve the arrangement specified for the blower. Do not drill a cap, remove a vent part, or add a generic vent to make a poor fit seem usable. If a seller cannot confirm the application or key features, keep looking.
Prepare safely before removal
Work outdoors with the blower switched off and cool. Keep it away from flames, sparks, and smoking. Wear eye protection and fuel-resistant gloves. Wipe dirt from around the cap before opening the tank so debris is less likely to fall into the fuel.
Check the tank neck before fitting a replacement. Look for cracks, damaged threads, dirt, or a distorted sealing surface. If the neck is cracked or deformed, a new cap may not solve the leak; have the tank serviced or replaced. Do not use sealant or pliers to compensate for damaged parts.
Field operation: fit, check, and restart
A correct cap should engage squarely and seal as designed without force. Clean the tank opening, install the listed cap, and check for leaks before starting. If fuel appears around the cap or you smell fuel, stop and fix the cause first. Do not operate a blower with a leaking tank or cap.
Step-by-step replacement
- Inspect: With the engine off and cool, remove the old cap without forcing it. Check the tank neck and cap threads for damage. Wipe away dirt, and inspect the sealing surface.
- Compare: Confirm that the replacement is the part listed for your full machine identification. Check that the gasket and any supplied vent or tether parts match the specified design.
- Fit: Place the cap squarely on the neck and engage its threads by hand. It should turn into place without cross-threading or unusual resistance. Tighten securely by hand as designed. Do not use pliers or overtighten.
- Check: Add only the correct premixed fuel, close the cap, and wipe the tank dry. Look for wetness and check for fuel odor before starting.
- Recheck: Start and operate the blower only as directed in its manual, with the blower tube secured and people clear of the discharge stream. Shut it down, let the engine and muffler cool, then inspect the cap area again.
If fuel leaks at any point, stop using the blower. A cap that does not seal, or a damaged tank neck, can let gasoline reach a hot engine or muffler and create a fire risk. Do not keep tightening a cap that will not seat correctly.
Two fitment examples to guide a decision
These are diagnostic examples, not reports of specific customer repairs. They show how I would sort common replacement questions without guessing at a part number.
- The cap threads on, but fuel seeps around it: Stop and check that the replacement is listed for the exact machine. Inspect the gasket and sealing surface, then examine the tank neck for cracks or distortion. A cap that turns onto the neck is not necessarily the right cap.
- The cap seems right but will not start squarely: Back it off and check the threads and part identification. Do not force it. A near-match can damage the tank neck, turning a cap replacement into a larger repair.
- A replacement listing says “fits Poulan”: Ask the seller for the exact 655BP product or serial cross-reference and confirmation of the sealing and vent arrangement. If the seller cannot provide it, use the IPL or consult a parts dealer instead.
The practical test is not whether a cap can be made to stay on. It is whether the correct part seats and seals without force and remains dry after the blower has run and cooled.
Maintenance & cap inspection
A fuel cap needs a sound seal and clean threads to do its job. Check it whenever you refuel, and replace a hardened, split, swollen, or missing gasket with the specified assembly. Keep dirt out of the tank opening, and leave the original vent design unchanged.
Inspect the cap and tank neck in good light. Look for a cracked cap, worn or damaged threads, a gasket that has become hard or misshapen, and dirt on the sealing surface. If the cap loosens easily, will not seat, or leaks after correct installation, stop and verify the part and tank condition.
Do not try to solve a fit problem by filing threads, adding tape, applying sealant, or modifying a vent. Such changes can interfere with the seal or the fuel system’s intended operation. If the cap is listed correctly but still will not seal, the tank neck or another component may need service.
The 655BP is a two-stroke backpack blower. Use the fuel-oil ratio on the blower’s own fuel label or in its operator’s manual. Some Poulan Pro two-stroke manuals specify 40:1, equal to 3.2 US fluid ounces of oil per 1 US gallon of gasoline, but that does not confirm the ratio for every machine. Verify before mixing; do not guess based on brand.
Storage & seasonal care
For storage, follow the 655BP operator’s manual for fuel and long-term storage instructions. Use fresh fuel mixed at the verified ratio and the recommended two-stroke oil. Store the blower and fuel away from heat and ignition sources, and recheck the cap and tank for leakage before the next use.
Before putting the blower away, wipe fuel from the tank and cap area and inspect for seepage. Keep the cap installed as designed, and do not block or alter its vent feature. Store the machine and fuel away from living areas, heat, flames, and other ignition sources.
Before the next season, inspect the cap, gasket, threads, and tank neck again. A dry exterior does not prove the cap is the right part, so keep your parts information with the blower’s manual. If there is a fuel odor or visible leak, do not start the engine until the source is found and repaired.
Frequently asked questions
These quick answers cover the main buying and fitment checks for a 655BP fuel cap. For a definite part match, use the full machine identification and the corresponding parts list. If either is unclear, ask a qualified parts dealer to confirm before ordering or operating.
Can I buy a gas cap by searching “655BP”?
Use that search to find candidates, not to confirm fit. Match the cap to the blower’s product and serial information and its corresponding illustrated parts list.
Is there one cap part number for every 655BP?
Do not assume so. The model name alone may not identify the correct product or serial variant. Confirm the listed cap for your specific machine.
Will a cap for another Poulan blower fit?
Not necessarily. Different models can use different threads, seals, or vent arrangements. Buy it only if the parts list or a reliable fitment reference confirms compatibility.
Can I use a chainsaw fuel cap?
Only if the correct parts reference explicitly lists that cap for your blower. A similar appearance or brand name is not enough.
Is an aftermarket cap safe to use?
It can be an option when the listing explicitly cross-references your exact machine and matches the threads, gasket, sealing surface, and specified vent or tether design.
How tight should I install the cap?
Engage it squarely and tighten securely by hand as designed. Do not force it, use pliers, or overtighten. If it will not seat, recheck the part and tank neck.
What if the cap fits but leaks?
Stop using the blower. Check the cap identification, gasket, sealing surface, and tank neck. Replace damaged parts or have the tank serviced before restarting.
Should I drill or alter a vent on a replacement cap?
No. Do not drill, remove, or modify vent features. Use the vent arrangement specified for the machine.
What fuel mix should I use after replacing the cap?
Follow the fuel label or operator’s manual for your specific blower. Do not guess the mix ratio based on the Poulan name or another model.
Can I keep using the blower if the leak is small?
No. Shut it down and let it cool. Fuel can reach a hot engine or muffler, so repair the leak before using the blower again.
(This article was written by one of our staff writers, Elliott Fowler. Visit our Meet the Team page.)
