Related Manuals for KTM 500EXC-F 2023
Summarization of Contents
DEAR KTM CUSTOMER
Vehicle Identification Number
Details on the location of the Vehicle Identification Number and engine number.
Owner's Manual Information
Notes regarding the manual's validity, specifications, and disclaimers.
Means of Representation
Symbols Used
Explanation of symbols used throughout the manual for clarity and safety.
Formats Used
Explanation of typographical formats like proprietary names and underlined terms.
Safety Advice
Use Definition – Intended Use
Defines the intended purpose and restrictions for different vehicle models.
Misuse
Describes dangers arising from using the vehicle outside its intended use.
Safety Advice
General instructions and importance of reading all safety information carefully.
Degrees of Risk and Symbols
Explains risk levels (Danger, Warning, Caution, Note) and their associated symbols.
Tampering Warning
Prohibits tampering with noise control systems and lists specific prohibited acts.
Safe Operation
Covers safe riding practices, including fitness and hazards like accidents and poisoning.
Protective Clothing
Emphasizes the importance of wearing appropriate protective gear for safety.
Work Rules
Outlines general rules for performing work on the vehicle, including tools and conditions.
Environment
Advises on responsible motorcycle use and proper disposal of fluids.
Owner's Manual
Stresses reading the manual and where to obtain further information.
Important Notes
Manufacturer Warranty, Implied Warranty
Details warranty conditions and requirements for authorized service.
Fuel, Auxiliary Substances
Notes on fuel hazards and proper usage according to the manual.
Spare Parts, Technical Accessories
Advises using approved parts and highlights potential liability for non-approved items.
Service
Explains the importance of regular service for performance and longevity.
Figures
Notes that figures may show special equipment and components might be disassembled.
Customer Service
Directs users to authorized dealers for questions and information.
View of Vehicle
View of Vehicle, Front Left (Example)
Identifies major components of the motorcycle from the front left view.
View of Vehicle, Rear Right (Example)
Identifies major components of the motorcycle from the rear right view.
Serial Numbers
Vehicle Identification Number
Shows the location of the VIN on the steering head.
Type Label
Details the location of type labels for different models.
Key Number (All EU models)
Indicates where the key number for the steering lock is stamped.
Engine Number
Shows the location of the engine number on the engine casing.
Fork Part Number
Specifies the location of the fork part number.
Shock Absorber Article Number
Indicates where the shock absorber article number is stamped.
Controls
Clutch Lever
Describes the clutch lever on the left handlebar and its operation.
Hand Brake Lever
Identifies the hand brake lever on the right handlebar for the front brake.
Throttle Grip
Describes the throttle grip on the right handlebar.
Stop Button
Locates the stop button on the left handlebar for EU models.
Stop Button (XCF-W)
Details the stop button on the left handlebar for XCF-W models and its functions.
Horn Button (All EU models)
Locates the horn button on the left handlebar and its operation.
Light Switch (All EU models)
Explains the light switch on the left handlebar for EU models and its positions.
Light Switch (XCF-W)
Describes the light switch for XCF-W models and its operation.
Turn Signal Switch (All EU models)
Locates the turn signal switch and its positions for EU models.
Emergency OFF Switch
Identifies the emergency OFF switch and its ignition states.
Start Button
Locates the start button and its function for both EU and XCF-W models.
Combination Switch (EXC-F SIX DAYS, XCF-W)
Explains the combination switch for changing engine mapping and traction control.
Overview of Indicator Lamps (All EU models)
Describes the function of various indicator lamps on the instrument cluster for EU models.
Overview of Indicator Lamps (XCF-W)
Details indicator lamps on the instrument cluster for XCF-W models.
Opening Fuel Tank Filler Cap
Provides instructions and safety warnings for opening the fuel tank cap.
Closing the Fuel Tank Filler Cap
Describes the procedure for closing the fuel tank filler cap.
Cold Start Button
Explains the function and operation of the cold start button.
Idle Speed Adjusting Screw
Describes how to adjust the idle speed using the adjusting screw.
Shift Lever
Locates the shift lever and explains gear positions.
Foot Brake Lever
Identifies the foot brake lever for the rear brake.
Side Stand
Locates the side stand and its use for parking.
Steering Lock (All EU models)
Explains the steering lock and its purpose.
Locking the Steering (All EU models)
Details the procedure for locking the motorcycle's steering.
Unlocking the Steering (All EU models)
Describes how to unlock the motorcycle's steering.
Combination Instrument
Combination Instrument Overview
Provides a general overview of the combination instrument and its buttons.
Activation and Test
Explains how to activate the instrument and perform a display test.
Setting Kilometers or Miles
Details the procedure for setting distance units and adjusting display values.
Setting the Combination Instrument
Describes how to activate, deactivate, and set functions within the instrument's setup menu.
Setting the Clock
Provides instructions for setting the time on the combination instrument.
Viewing the Lap Time
Explains how to view and reset lap times recorded by the stopwatch.
Display Mode SPEED (speed)
Describes how to display the current speed in Km/h or Mph.
Display Mode SPEED/H (operating hours)
Explains how to view engine operating hours and their importance for service.
Setup Menu
Describes how to access the setup menu to configure instrument functions.
Adjusting the Unit of Measurement
Details how to change the unit of measurement (Km/h or Mph) for speed and distance.
Display Mode SPEED/CLK (time)
Explains how to view the current time on the display.
Setting the Clock
Provides detailed steps for setting the clock display.
Display Mode SPEED/LAP (lap time)
Describes how to use the display for timing lap times.
Viewing the Lap Time
Explains how to view recorded lap times and reset the stopwatch.
Display Mode SPEED/ODO (odometer)
Describes how to view the total distance traveled (odometer).
Display Mode SPEED/TR1 (trip master 1)
Explains the trip master 1 function for measuring distances and resetting.
Display Mode SPEED/TR2 (trip master 2)
Details the trip master 2 function and how to adjust it.
Adjusting TR2 (trip master 2)
Provides specific steps for manually setting the trip master 2 value.
Display Mode SPEED/A1 (average speed 1)
Explains how average speed 1 is calculated and displayed.
Display Mode SPEED/A2 (average speed 2)
Describes how average speed 2 is calculated and displayed.
Display Mode SPEED/S1 (stop watch 1)
Explains the function of stop watch 1 and its reset procedure.
Display Mode SPEED/S2 (stop watch 2)
Details the manual stop watch 2 function and its operation.
Table of Functions
Summarizes the conditions and functions available for the combination instrument.
Preparing for Use
Advice on Preparing for First Use
Covers crucial safety advice and initial checks before the first ride.
Running-in the Engine
Provides guidelines for the engine break-in period to ensure longevity.
Starting Power of Lithium-Ion Batteries at Low Temperatures
Addresses potential starting issues with lithium-ion batteries in cold conditions.
Preparing the Vehicle for Difficult Operating Conditions
Outlines general preparations for riding in challenging environments.
Preparing the Vehicle for Riding on Dry Sand
Specific steps to prepare the vehicle for riding on dry sand.
Preparing the Vehicle for Riding on Wet Sand
Details preparations required for riding on wet sand conditions.
Preparing the Vehicle for Riding on Wet and Muddy Circuits
Instructions for preparing the bike for wet and muddy terrain.
Preparing Vehicle for High Temperatures or Slow Riding
Advice on adjusting the vehicle for hot weather and slow riding conditions.
Preparing the Vehicle for Low Temperatures or Snow
Guidance on preparing the motorcycle for cold weather and snow.
Riding Instructions
Checks and Maintenance Measures When Preparing for Use
Essential pre-ride checks and maintenance tasks for safe operation.
Starting the Vehicle
Instructions and warnings related to starting the motorcycle's engine.
Activating Traction Control (EXC-F SIX DAYS, XCF-W)
Explains how to activate and use the traction control system.
Starting Off
Guidance on safely starting the motorcycle from a standstill.
Shifting, Riding
Describes the process of shifting gears and general riding techniques.
Braking
Essential advice and warnings regarding motorcycle braking techniques.
Stopping, Parking
Instructions and safety precautions for stopping and parking the motorcycle.
Transporting
Guidelines for safely transporting the motorcycle.
Refueling
Safety instructions and procedures for refueling the motorcycle.
Service Schedule
Additional Information
Notes on service intervals, country-specific conditions, and KTM Dealer.net.
Required Work
Lists essential maintenance tasks based on operating hours.
Recommended Work
Lists recommended maintenance tasks based on time and operating hours.
Tuning the Chassis
Checking the Basic Chassis Setting with Rider's Weight
Explains how to set up the chassis based on rider weight for optimal handling.
Compression Damping of the Shock Absorber
Introduces high-speed and low-speed compression damping concepts.
Adjusting the Low-Speed Compression Damping of the Shock Absorber
Details how to adjust the low-speed compression damping.
Adjusting the High-Speed Compression Damping of the Shock Absorber
Provides instructions for adjusting high-speed compression damping.
Adjusting the Rebound Damping of the Shock Absorber
Explains how to adjust the rebound damping of the shock absorber.
Measuring the Dimension of the Rear Wheel Unloaded
Describes the process for measuring rear wheel unloaded dimension.
Checking the Static Sag of the Shock Absorber
Details how to check the static sag of the rear shock absorber.
Checking the Riding Sag of the Shock Absorber
Explains how to check the riding sag of the rear shock absorber.
Adjusting the Spring Preload of the Shock Absorber
Provides step-by-step instructions for adjusting the shock absorber spring preload.
Adjusting the Riding Sag
Details how to adjust the riding sag by selecting and mounting springs.
Checking the Basic Setting of the Fork
Covers checking the fork's basic settings and potential issues.
Adjusting the Compression Damping of the Fork
Explains how to adjust the compression damping on the fork legs.
Adjusting the Rebound Damping of the Fork
Details how to adjust the rebound damping on the fork legs.
Adjusting the Spring Preload of the Fork
Provides instructions for adjusting the spring preload on the front fork.
Handlebar Position
Shows how handlebar holders can be mounted in different positions.
Adjusting the Handlebar Position
Warns about safety risks with repaired handlebars and when to replace.
Handlebar Position (EXC-F EU, XCF-W)
Details handlebar mounting options for specific models.
Handlebar Position (EXC-F SIX DAYS EU)
Details handlebar mounting options for the EXC-F SIX DAYS EU model.
Service Work on the Chassis
Raising the Motorcycle with the Lift Stand
Provides instructions for safely raising the motorcycle using a lift stand.
Removing the Motorcycle from the Lift Stand
Details the procedure for safely removing the motorcycle from the lift stand.
Bleeding the Fork Legs
Explains how to bleed excess pressure from the fork legs.
Cleaning the Dust Boots of the Fork Legs
Instructions for cleaning fork dust boots to prevent seal leaks.
Removing the Fork Protector
Steps for removing the fork protectors from both fork legs.
Installing the Fork Protector
Instructions for installing the fork protectors onto the fork legs.
Removing the Fork Legs
Details the process of removing the front fork legs from the motorcycle.
Installing the Fork Legs
Provides steps for correctly installing the front fork legs.
Removing the Lower Triple Clamp (EXC-F EU, XCF-W)
Step-by-step guide to removing the lower triple clamp for specific models.
Removing the Lower Triple Clamp (EXC-F SIX DAYS EU)
Step-by-step guide to removing the lower triple clamp for the EXC-F SIX DAYS EU.
Installing the Lower Triple Clamp (EXC-F EU, XCF-W)
Instructions for installing the lower triple clamp on specific models.
Installing the Lower Triple Clamp (EXC-F SIX DAYS EU)
Steps for installing the lower triple clamp on the EXC-F SIX DAYS EU model.
Checking Steering Head Bearing Play
Details how to check for play in the steering head bearings.
Adjusting the Steering Head Bearing Play
Instructions for adjusting steering head bearing play.
Adjusting the Steering Head Bearing Play (EXC-F EU, XCF-W)
Specific steps to adjust steering head bearing play for EU and XCF-W models.
Adjusting the Steering Head Bearing Play (EXC-F SIX DAYS EU)
Specific steps to adjust steering head bearing play for the EXC-F SIX DAYS EU model.
Lubricating the Steering Head Bearing
Explains the lubrication process for steering head bearings.
Removing Front Fender
Step-by-step guide to removing the front fender.
Installing Front Fender
Instructions for installing the front fender.
Removing the Shock Absorber
Details the procedure for removing the rear shock absorber.
Installing the Shock Absorber
Provides steps for correctly installing the rear shock absorber.
Removing the Seat
Steps for removing the motorcycle seat.
Mounting the Seat
Instructions for correctly mounting the motorcycle seat.
Removing the Air Filter Box Cover
Details how to remove the air filter box cover.
Installing the Air Filter Box Cover
Instructions for installing the air filter box cover.
Removing the Air Filter
Explains how to safely remove the air filter from the air filter box.
Installing the Air Filter
Provides steps for correctly installing the air filter.
Cleaning the Air Filter and Air Filter Box
Details the procedure for cleaning the air filter and its box.
Preparing Air Filter Box Cover for Securing
Instructions for preparing the air filter box cover for securing.
Removing the Main Silencer
Step-by-step guide to removing the main silencer assembly.
Installing the Main Silencer
Provides instructions for installing the main silencer assembly.
Cleaning the Spark Arrestor (XCF-W)
Specific instructions for cleaning the spark arrestor on XCF-W models.
Changing the Glass Fiber Yarn Filling of the Main Silencer
Details the procedure for replacing the glass fiber yarn filling in the main silencer.
Removing the Fuel Tank
Step-by-step instructions for safely removing the fuel tank.
Removing the Fuel Tank (All EU models)
Specific steps for removing the fuel tank on EU models.
Removing the Fuel Tank (XCF-W)
Specific steps for removing the fuel tank on XCF-W models.
Installing the Fuel Tank
Provides instructions for correctly installing the fuel tank.
Installing the Fuel Tank (All EU models)
Installation steps for the fuel tank on EU models.
Installing the Fuel Tank (XCF-W)
Installation steps for the fuel tank on XCF-W models.
Checking for Chain Dirt Accumulation
How to check the motorcycle chain for dirt buildup.
Cleaning the Chain
Detailed procedure for cleaning the motorcycle chain.
Checking the Chain Tension
Explains how to check and measure chain tension.
Adjusting the Chain Tension
Provides steps to adjust the chain tension correctly.
Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide
Instructions for inspecting wear on chain, sprockets, and guides.
Checking the Frame
How to check the motorcycle frame for damage or deformation.
Checking the Link Fork
Instructions for inspecting the link fork for damage or wear.
Checking the Throttle Cable Routing
How to check the routing and condition of the throttle cables.
Checking the Rubber Grip
How to check handlebar rubber grips for damage and wear.
Adjusting the Basic Position of the Clutch Lever
How to adjust the clutch lever position for rider comfort.
Checking/Correcting the Fluid Level of the Hydraulic Clutch
Procedure for checking and correcting the hydraulic clutch fluid level.
Changing the Hydraulic Clutch Fluid
Detailed steps for changing the hydraulic clutch fluid.
Removing the Engine Guard (EXC-F SIX DAYS, XCF-W)
Steps for removing the engine guard on specific models.
Installing the Engine Guard (EXC-F SIX DAYS, XCF-W)
Steps for installing the engine guard on specific models.
Brake System
Adjusting the Basic Position of the Hand Brake Lever
How to adjust the hand brake lever position for rider comfort.
Checking the Brake Discs
How to check brake disc thickness and for damage.
Checking the Front Brake Fluid Level
How to check the front brake fluid level and identify potential issues.
Adding the Front Brake Fluid
Procedure for adding front brake fluid and safety warnings.
Adding the Front Brake Fluid (All EU models)
Adding front brake fluid for EU models.
Adding the Front Brake Fluid (XCF-W)
Adding front brake fluid for XCF-W models.
Checking the Front Brake Linings
How to check front brake lining thickness and for damage.
Changing the Brake Linings of the Front Brake
Procedure for changing the front brake linings.
Changing the Brake Linings of the Front Brake (All EU models)
Front brake lining change for EU models.
Checking the Rear Brake Linings
How to check rear brake lining thickness and for damage.
Changing the Rear Brake Linings
Procedure for changing rear brake linings.
Changing the Rear Brake Linings (All EU models)
Rear brake lining change for EU models.
Checking the Free Travel of Foot Brake Lever
How to check and set the free travel of the foot brake lever.
Adjusting the Basic Position of the Foot Brake Lever
How to adjust the foot brake lever position for rider comfort.
Checking the Rear Brake Fluid Level
How to check the rear brake fluid level and identify potential issues.
Adding Rear Brake Fluid
Procedure for adding rear brake fluid and safety warnings.
Adding Rear Brake Fluid (XCF-W)
Adding rear brake fluid for XCF-W models.
Checking the Rear Brake Linings
How to check rear brake lining thickness and for damage.
Changing the Rear Brake Linings
Procedure for changing rear brake linings.
Changing the Rear Brake Linings (XCF-W)
Rear brake lining change for XCF-W models.
Wheels, Tires
Removing the Front Wheel
Step-by-step guide to removing the front wheel.
Installing the Front Wheel
Instructions for correctly installing the front wheel.
Removing the Rear Wheel
Step-by-step guide to removing the rear wheel.
Installing the Rear Wheel
Instructions for correctly installing the rear wheel.
Checking the Tire Condition
How to check tires for cuts, damage, and tread depth.
Checking Tire Pressure
How to check and adjust tire pressure for optimal performance.
Checking Spoke Tension
Procedure for checking spoke tension and torque.
Electrical System
Removing the 12-V Battery
Step-by-step guide to safely removing the 12-V battery.
Installing the 12-V Battery
Instructions for correctly installing the 12-V battery.
Charging the 12-V Battery
Guidance on properly charging the 12-V battery, including safety and maintenance.
Charging the 12-V Battery (Main Work)
Details on connecting a charger and charging parameters.
Changing Main Fuse
Procedure for changing the main fuse, including safety warnings.
Changing the Fuses of Individual Electrical Power Consumers
How to identify and replace fuses for various electrical components.
Removing the Headlight Mask with the Headlight
Step-by-step guide to removing the headlight assembly.
Installing the Headlight Mask with the Headlight
Instructions for reinstalling the headlight assembly.
Changing the Headlight Bulb
Procedure for replacing the headlight bulb.
Checking the Headlight Setting
How to check and verify the correct headlight beam alignment.
Adjusting the Headlight Range
How to adjust the headlight beam range for optimal visibility.
Changing the Turn Signal Bulb (All EU models)
Procedure for changing turn signal bulbs on EU models.
Changing the Combination Instrument Battery
Steps for replacing the battery in the combination instrument.
Diagnostics Connector
Locates the diagnostics connector under the seat.
Cooling System
Cooling System
Overview of the cooling system components and function.
Checking the Antifreeze and Coolant Level
Instructions for checking coolant level and antifreeze protection.
Checking the Coolant Level
Detailed procedure for checking the coolant level in the radiator.
Draining the Coolant
Step-by-step guide to draining the coolant from the system.
Refilling Coolant
Procedure for refilling the cooling system with coolant.
Changing the Coolant
Instructions for a complete coolant change, including safety.
Changing the Coolant (Main Work)
Continues coolant change procedure with specific steps.
Tuning the Engine
Checking the Play in the Throttle Cable
How to check throttle cable play and potential adjustments needed.
Adjusting the Play in the Throttle Cable
Detailed steps for adjusting throttle cable play.
Adjusting the Characteristic Map of the Throttle Response
How to change the engine's throttle response by modifying the guide plate.
Changing the Mapping (EXC-F SIX DAYS, XCF-W)
How to select different engine mapping modes using the combination switch.
Adjusting the Idle Speed
Procedure for setting the engine's idle speed correctly.
Teaching the Throttle Valve Position
Explains how to retrain the throttle valve position for the control unit.
Checking the Basic Position of the Shift Lever
How to check the shift lever position relative to the rider's boot.
Adjusting the Basic Position of the Shift Lever
Steps for adjusting the shift lever's position.
Service Work on the Engine
Changing the Fuel Screen
Procedure for replacing the fuel filter screen.
Checking the Engine Oil Level
How to check the engine oil level using the viewer.
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screens
Comprehensive guide to changing engine oil, filter, and cleaning oil screens.
Changing the Engine Oil and Oil Filter (Main Work)
Continues the engine oil and filter change process.
Adding Engine Oil
Instructions for adding engine oil to the correct level.
Adding Engine Oil (Main Work)
Continues the engine oil addition procedure.
Cleaning, Care
Cleaning the Motorcycle
Guidelines and warnings for cleaning the motorcycle correctly.
Checks and Maintenance Steps for Winter Operation
Specific maintenance procedures for winter storage and use.
Storage
Storage
Steps to take when preparing the motorcycle for long-term storage.
Preparing for Use After Storage
Steps to follow when taking the motorcycle out of storage.
Troubleshooting
Troubleshooting: Engine Cannot Be Cranked (Starter Motor)
Lists possible causes and actions for starter motor issues.
Troubleshooting: Engine Turns But Does Not Start
Common causes and solutions when the engine won't start.
Troubleshooting: Engine Does Not Speed Up
Potential reasons and fixes when the engine fails to accelerate.
Troubleshooting: Engine Has Too Little Power
Diagnosing and resolving issues related to low engine power.
Troubleshooting: The Engine Dies During the Trip
Causes and solutions for the engine unexpectedly stopping while riding.
Troubleshooting: Engine Overheats
Identifying and fixing causes of engine overheating.
Troubleshooting: Malfunction Indicator Lamp Lights Up or Flashes
Interpreting and addressing malfunction indicator lamp warnings.
Troubleshooting: High Oil Consumption
Diagnosing and resolving issues related to excessive engine oil consumption.
Troubleshooting: 12-V Battery Discharged
Causes and solutions for a discharged 12-V battery.
Troubleshooting: Values in Combination Instrument Deleted
Reasons for deleted instrument data and potential fixes.
Troubleshooting: The High Beam, Low Beam, Tail Light, Position Light, and License Plate Lamp Are Not Working
Troubleshooting steps for lighting system failures.
Troubleshooting: The Horn, Brake Light, Turn Signal, and Radiator Fan Are Not Working
Diagnosing issues with horn, brake light, turn signals, and fan.
Blink Code
Blink Code for Malfunction Indicator Lamp
Lists malfunction indicator lamp blink codes and associated error conditions.
Blink Code for Malfunction Indicator Lamp (continued)
Continues listing blink codes and error conditions for the malfunction indicator lamp.
Technical Data
Engine
Provides detailed specifications for the engine.
Engine Tightening Torques
Lists torque specifications for various engine components.
Capacities
Details fluid capacities for engine oil, coolant, and fuel.
Chassis
Provides technical specifications for the chassis, fork, and suspension.
Fork
Technical data for the fork, including damping and preload settings.
Electrical System
Specifications for electrical components like battery, fuses, and lights.
Tires
Tire specifications and recommendations.
Shock Absorber
Technical data for the shock absorber, including damping and sag.
Chassis Tightening Torques
Lists torque specifications for various chassis components.
Substances
Brake fluid DOT 4 / DOT 5.1
Details specifications and recommended suppliers for brake fluid.
Coolant
Information on coolant requirements, antifreeze protection, and recommended types.
Engine oil (SAE 10W/50)
Specifications and recommended suppliers for engine oil.
Fork oil (SAE 4) (48601166S1)
Specifications and recommendations for fork oil.
Shock absorber fluid (SAE 2.5) (50180751S1)
Specifications and recommendations for shock absorber fluid.
Super unleaded (ROZ 95)
Fuel requirements and warnings about ethanol and methanol content.
Auxiliary Substances
Air filter cleaner
Recommended air filter cleaner and its supplier.
Chain cleaner
Recommended chain cleaner and its supplier.
Fuel additive
Recommended fuel additive and its supplier.
High viscosity grease
Recommended high viscosity grease and its supplier.
Long-life grease
Recommended long-life grease and its supplier.
Motorcycle cleaner
Recommended motorcycle cleaner and its supplier.
Off-road chain spray
Recommended off-road chain spray and its supplier.
Oil for foam air filter
Recommended oil for foam air filters and its supplier.
Preserving materials for paints, metal and rubber
Recommended preserving materials and their supplier.
Silicone spray
Recommended silicone spray and its supplier.
Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
Recommended special cleaner and its supplier.
Universal oil spray
Recommended universal oil spray and its supplier.
Standards
JASO T903 MA2
Explains the JASO T903 MA2 standard for motorcycle engine oils.
SAE
Explains SAE viscosity classifications for oils.
Index of Special Terms
OBD
Defines OBD as On-board diagnosis system for vehicle electronics.
List of Symbols
Yellow and Orange Symbols
Explains symbols indicating error conditions and driving aids.
Green and Blue Symbols
Explains symbols providing information about vehicle status.
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