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HOW TO RESOURCE: Boliy Pro3600Si Generator Case

How to disassemble and reassemble the red casing on the Boliy Pro3600Si Inverter Generator

DISASSEMBLING & REASSEMBLING BOLIY GENERATOR CASE: For some aspects of your Boliy generator maintenance, the polyurethane panels will need to be removed. The job will be easier if you follow certain procedures.

TIP: For best results, keep generator vertical as casing is being removed or replaced. Since you will need to access screws on underside of casing, it is convenient to rest generator on a table or work bench for easy access.


TIP: The only casing panel which ought never to be removed for routine maintenance is the front one(containing outlets, recoil start, etc.). Because play in the electrical wires is limited, stretching or damaging wiring, or breaking a connection, can occur when front of casing is disconnected from underside panel.

TIP: Some maintenance can be done just fine through available utility doors in the casing. Spark-plug replacement and oil change should not require disassembly. Draining used engine oil is accomplished by removing oblong rubber cap on underside of generator to expose the drain bolt.

TIP: Air-filter maintenance and carburetor adjustments will require panel removal. Boliy service guidelines specify that the left-end panel(left as you face front of generator) needs to be removed for these procedures. Sometimes, regarding carburetor work especially, it is simpler to work when both side and back panels have been removed.

Adhering to a methodology during disassembly is not critical. However, we recommend the following:


A) Remove 4 screws securing left-end panel; panel should slide out.

B) Remove 2 screws securing right-end panel(where muffler resides); panel should slide out.

C) Remove 4 bolts attaching handles to front and back panels. Handles can now be extracted.

D) Remove cap from gas tank. This allows you to lift out top panel. When panel has been removed, replace fuel-cell cap to keep dust and debris from entering tank.

E) Remove 2 screws that fasten back generator panel to gas tank.


F) First remove 2 corner screws(1 found at each bottom outside corner of back panel); these are secured by bolts inside casing, a point to remember during reassembly.

G) There are 6 screws attaching back panel to underside pan. When these have been removed, rear panel can be extracted.

REMOVING GAS TANK(if necessary)

H) The gas tank is now connected by 2 screws to generator’s front panel; after these have been removed, the gas tank will slide out - after you have disconnected the fuel line.

I) Locate fuel filter(white plastic and bell-shaped) inside of front panel near FUEL VALVE. The best place to disconnect line is at top of the fuel filter.

IMPORTANT: if fuel remains in tank, line must be clamped before it is disconnected to prevent gushing. Use standard plastic clamp in line above fuel filter. Be sure that clamp is tightened to maximum extent, and that you clamp line prior to disconnecting.

Also be certain that fuel filter sits in upright(vertical) position in generator casing to prevent accidental drainage.


Reassembly of your generator casing is basically a reverse of the disassembly process. There are a few tips we can offer to make it easier:

A) If gas tank was removed, reposition; the fuel cell sits atop the front and back panel tabs. Since back panel will not be in place, attach gas tank to front panel with 2 screws.

B) Test-fit back panel. There are two things to keep in mind:

FIRST: before back panel is secured, be certain that the two clear tubes coming from carburetor have been pulled through. Try wrapping two or three coils of masking tape around them to keep them from sliding back in!

SECOND: there are ribs at bottom of back panel(one at either end) which must rest on rim of the underside pan. When these panels are properly aligned, the fit should be snug.

C) If panel is snug(indicating that ribs are properly positioned), and clear tubes from carburetor are protruding through openings, then attach 2 end screws(at bottom corners of back panel).

REMEMBER: that these screws are fastened to bolts on inside of casing.

D) Attach and tighten 2 screws holding fuel cell to back panel.

E) Fit top panel into place(over gas tank). Remember to immediately replace gas tank cap.

F) Fit both side panels into place; at this point, they shouldn’t be tightened down.

G) Reposition handles between front and back generator panels; apply handle bolts loosely.

H) Insert 6 screws into side panels and tighten down. Careful not to over-tighten; too much muscle can twist them right through the plastic!

I) Tighten down 4 handle bolts.

J) Install and tighten down the 6 screws on underside of back panel.

K) Recheck tightness of all screws and bolts holding casing in place. You are done!

Need Help? Call 866-613-9115
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T-Rex Generators distributes products from many different standby and portable generator manufacturers at substantially discounted prices. These represented companies include: Asco automatic transfer switches, Briggs & Stratton generators, Winco generators, Generac Generators, GenTran transfer switches, Reliance Controls Transfer Switches, and Zenith automatic transfer switches. T-Rex also carries Honda powered generators which have the same time-tested Honda engines as the substantially more expensive Honda generator brand units.