got wet from ridding in rain ?, washing it down ?, then never got dried. most of what I see is wear areas from plastics rubbing the frame. only way your going to fix that ?, is a complete tear down, some grinding/sanding , then a paint job. if you decide to give it a power washer job ?, MAKE SURE YOU BLOCK OFF ANY AND ALL AREAS OF WATER GETTING INTO THE MOTOR !!!. stay away from any electrical connection as much as posb if you use a power washer ?. this will not come out very well..lol. if you do get water in the connectors ?, pull them apart, blow them out with an air compressor , then spray ( what I do anyway ) wd-40 into them. I don't ride in anything over the center of my center caps on my wheels, so I know I wont damage my atv. if I wash it down with a hose or power washer ?, I never..ever..aim it at anything electrical, or near anywhere it can get into my engine..such as vent lines, carb, air boxes.
Okay, I admit that over the years he never got washed and dried a lot of times and that's on me. However, I can guarantee beyond any doubt that this machine has NEVER been in water or mud higher than the center of the wheel caps, even when my friend rode it. I was with him and his wife. The almost 20 years prior to this I was the only person who rode him.
"Complete tear down" is enough to keep me awake at night, but I understand and will do this as far as I can. I'm having trouble getting the front fender off because of the headlight wiring. There is no connector to disconnect. The wires are all "spliced" together. I guess I'll have to take out the entire headline assembly. When I did this on my hubby's Yamaha it was a nightmare getting it back together. The back rack and fender should come off without too much trouble, I hope.
I'll skip the pressure washer and do it by hand since I can't be sure I won't wet something I shouldn't. As @Goober
said, doing it by hand will allow me see where all those hoses are routed and electrical connections are. I will clean the connections of dust/dirt and use proper grease before reconnecting.
I did find a manual on the Forum but Google only allows me to print one page at a time. I don't know why.
As always, thank you for your great advice and guidance.