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Suzuki VLR1800 Manuals
Manuals and User Guides for Suzuki VLR1800. We have
1
Suzuki VLR1800 manual available for free PDF download: Service Manual
Suzuki VLR1800 Service Manual (624 pages)
Brand:
Suzuki
| Category:
Motorcycle
| Size: 56.54 MB
Table of Contents
Table of Contents
65
Precautions
69
Precautions for Engine
69
Engine General Information and Diagnosis
70
General Description
70
Injection Timing Description
70
Self-Diagnosis Function
71
Schematic and Routing Diagram
73
FI System Wiring Diagram
73
Terminal Alignment of ECM Coupler
74
Component Location
75
FI System Parts Location
75
Diagnostic Information and Procedures
77
Engine Symptom Diagnosis
77
Self-Diagnostic Procedures
81
Use of SDS Diagnosis Reset Procedures
83
Show Data When Trouble (Displaying Data at the Time of DTC)
84
SDS Check
86
DTC Table
89
Fail-Safe Function Table
91
FI System Troubleshooting
92
Malfunction Code and Defective Condition Table
93
DTC "C12" (P0335): CKP Sensor Circuit Malfunction
96
DTC "C13" (P1750-H/L) or "C17" (P0105-H/L): IAP Sensor Circuit Malfunction
99
DTC "C14" (P0120-H/L): TP Sensor Circuit Malfunction
107
DTC "C15" (P0115-H/L): ECT Sensor Circuit Malfunction
116
DTC "C21" (P0110-H/L): IAT Sensor Circuit Malfunction
121
DTC "C23" (P1651-H/L): to Sensor Circuit Malfunction
126
DTC "C24" (P0351), "C25" (P0352), "C26" (P0353) or "C27" (P0354): Ignition System Malfunction
133
DTC "C28" (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction
133
DTC "C29" (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction
137
DTC "C31" (P0705): GP Switch Circuit Malfunction
144
DTC "C32" (P0201), "C33" (P0202): Fuel Injector Circuit Malfunction
146
DTC "C40" (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction
149
DTC "C41" (P0230-H/L): FP Relay Circuit Malfunction
153
DTC "C42" (P1650): IG Switch Circuit Malfunction
155
DTC "C44" (P0156) or "C64" (P0130): O2 Sensor (O2S) Circuit Malfunction (for
156
DTC "C46" (P1657-H/L or P1658): EXCV Actuator Circuit Malfunction
160
DTC "C60" (P0480): Cooling Fan Relay Circuit Malfunction
173
DTC "C61" (P1656): PAIR Control Solenoid Valve Circuit Malfunction
176
DTC "C62" (P0443): EVAP System Purge Control Solenoid Valve Circuit Malfunction (for
179
Specifications
183
Service Data
183
Special Tools and Equipment
184
Special Tool
184
Emission Control Devices
186
Precautions
186
Precautions for Emission Control Devices
186
General Description
186
Fuel Injection System Description
186
Crankcase Emission Control System Description
187
Exhaust Emission Control System Description
188
Noise Emission Control System Description
189
Evaporative Emission Control System
190
Schematic and Routing Diagram
191
PAIR System Hose Routing Diagram
191
EVAP Canister Hose Routing Diagram
193
Repair Instructions
194
Oxygen Sensor (O2S) Removal and Installation
194
Heated Oxygen Sensor (O2S) Inspection
195
PAIR Reed Valve Removal and Installation
195
PAIR Control Solenoid Valve Removal and Installation
195
PAIR System Inspection
196
Crankcase Breather (PCV) Hose Inspection
197
Crankcase Breather (PCV) Hose Cover Removal and Installation
197
Crankcase Breather (PCV) Cover Inspection
198
Evaporative Emission Control System
198
Removal and Installation (Only for
198
Evaporative Emission Control System Inspection (for E-33 Only)
199
Specifications
201
Service Data
201
Tightening Torque Specifications
201
Special Tools and Equipment
201
Recommended Service Material
201
Special Tool
201
Engine Electrical Devices
202
Precautions
202
Precautions for Engine Electrical Device
202
Component Location
202
Engine Electrical Components Location
202
Diagnostic Information and Procedures
202
Engine Symptom Diagnosis
202
Repair Instructions
202
ECM Removal and Installation
202
CKP Sensor Inspection
202
IAP Sensor Removal and Installation
203
TP Sensor Inspection
203
TP Sensor Removal and Installation
203
TP Sensor Adjustment
203
IAT Sensor Removal and Installation
204
ECT Sensor Removal and Installation
204
ECT Sensor Inspection
205
TO Sensor Removal and Installation
206
TO Sensor Inspection
206
STP Sensor Inspection
206
STP Sensor Adjustment
206
STP Sensor Removal and Installation
207
STV Actuator Inspection
208
STV Actuator Removal and Installation
208
ISC Valve Inspection
208
ISC Valve Removal and Installation
208
ISC Valve Preset and Opening Initialization
208
O2 Sensor Inspection
209
O2 Sensor Removal and Installation
209
GP Switch Inspection
209
GP Switch Removal and Installation
209
Specifications
210
Service Data
210
Tightening Torque Specifications
210
Special Tools and Equipment
211
Recommended Service Material
211
Special Tool
211
Engine Mechanical
212
Schematic and Routing Diagram
212
Camshaft and Sprocket Assembly Diagram
212
Throttle Cable Routing Diagram
213
Diagnostic Information and Procedures
214
Engine Mechanical Symptom Diagnosis
214
Compression Pressure Check
214
Repair Instructions
215
Engine Components Removable with the Engine in Place
215
Air Cleaner Element Removal and Installation
217
Air Cleaner Element Inspection and Cleaning
217
Air Cleaner Chamber Removal and Installation
217
Throttle Body Components
219
Throttle Body Construction
220
ISC Valve Removal and Installation
221
Throttle Body Removal and Installation
221
Throttle Body Disassembly and Assembly
223
Throttle Body Inspection and Cleaning
226
Throttle Valve Synchronization
227
ISC Valve Reset
229
Engine Assembly Removal
229
Engine Assembly Installation
234
Engine Top Side Disassembly
236
Engine Top Side Assembly
241
Valve Clearance Inspection and Adjustment
254
Cylinder Head Cover Inspection
254
Camshaft Inspection
254
Camshaft Sprocket and Automatic-Decomp. Inspection
256
Cam Chain Tension No. 1 and No. 2 Adjuster Inspection
256
Cam Chain Guide No. 1, No. 2 and No. 3
257
Inspection
257
Cam Chain Tensioner No. 1 Inspection
257
Cylinder Head Cover Disassembly and Assembly
257
PAIR Reed Valve / PAIR Reed Valve Cover Inspection
258
Cylinder Head Disassembly and Assembly
258
Cylinder Head Related Parts Inspection
262
Valve Guide Replacement
264
Valve Seat Repair
265
Cam Chain Tensioner No. 2 Inspection
266
Cylinder Inspection
266
Piston Ring Removal and Installation
267
Piston and Piston Ring Inspection
268
Engine Bottom Side Disassembly
270
Engine Bottom Side Assembly
279
Conrod Removal and Installation
295
Conrod / Crankshaft Inspection
297
Conrod Crank Pin Bearing Inspection and Selection
297
Crankshaft Journal Bearing Inspection and Selection
299
Crankshaft Thrust Clearance Inspection and Selection
301
Balancer Driven Gear Disassembly and Assembly
303
Balancer Shaft Parts Inspection
305
Specifications
306
Service Data
306
Tightening Torque Specifications
308
Special Tools and Equipment
309
Recommended Service Material
309
Special Tool
310
Engine Lubrication System
313
Precautions
313
Precautions for Engine Oil
313
Schematic and Routing Diagram
313
Engine Lubrication System Chart Diagram
313
Diagnostic Information and Procedures
314
Engine Lubrication Symptom Diagnosis
314
Oil Pressure Check
314
Repair Instructions
315
Engine Oil and Filter Replacement
315
Engine Oil Level Inspection
315
Oil Pan / Oil Strainer / Oil Pressure Regulator
315
Removal and Installation
315
Oil Pressure Regulator / Oil Strainer Inspection
317
Oil Cooler Removal and Installation
318
Oil Pressure Switch Removal and Installation
319
Oil Pressure Switch Inspection
319
Oil Jet Removal and Installation
319
Oil Jet / Oil Gallery Jet Inspection
321
Oil Pump Removal and Installation
321
Oil Pump Inspection
322
Specifications
323
Service Data
323
Tightening Torque Specifications
323
Special Tools and Equipment
324
Recommended Service Material
324
Special Tool
324
Engine Cooling System
325
Precautions
325
Precautions for Engine Cooling System
325
Precautions for Engine Coolant
325
General Description
325
Schematic and Routing Diagram
326
Cooling Circuit Diagram
326
Water Hose Routing Diagram
327
Diagnostic Information and Procedures
328
Engine Cooling Symptom Diagnosis
328
Repair Instructions
328
Cooling Circuit Inspection
328
Radiator Cap Inspection
329
Radiator Inspection and Cleaning
329
Radiator / Cooling Fan Motor Removal and Installation
329
Water Hose Inspection
330
Water Hose Removal and Installation
331
Radiator Reservoir Tank Inspection
331
Radiator Reservoir Tank Removal and Installation
332
Cooling Fan Inspection
332
Cooling Fan Relay Inspection
333
ECT Sensor Removal and Installation
333
ECT Sensor Inspection
333
Thermostat Removal and Installation
333
Thermostat Inspection
334
Water Pump Components
335
Water Pump Removal and Installation
336
Water Pump Disassembly and Assembly
337
Water Pump Related Parts Inspection
340
Specifications
341
Service Data
341
Tightening Torque Specifications
341
Special Tools and Equipment
342
Recommended Service Material
342
Special Tool
342
Fuel System
343
Precautions
343
Precautions for Fuel System
343
General Description
344
Fuel System Description
344
Diagnostic Information and Procedures
345
Fuel System Diagnosis
345
Repair Instructions
346
Fuel Pressure Inspection
346
Fuel Pump Inspection
346
Fuel Discharge Amount Inspection
347
Fuel Pump Relay Inspection
348
Fuel Hose Inspection
348
Fuel Level Gauge Inspection
348
Fuel Level Indicator Inspection
348
Fuel Level Indicator Switch (Thermistor) Inspection
348
Fuel Tank Construction
349
Fuel Tank Removal and Installation
350
Fuel Pump Components
351
Fuel Pump Assembly / Fuel Level Gauge Removal and Installation
352
Fuel Pump Disassembly and Assembly
353
Fuel Mesh Filter Inspection and Cleaning
354
Fuel Injector / Fuel Delivery Pipe Removal and Installation
355
Fuel Injector Inspection and Cleaning
355
Specifications
355
Service Data
355
Tightening Torque Specifications
355
Special Tools and Equipment
356
Recommended Service Material
356
Special Tool
356
Ignition System
357
Schematic and Routing Diagram
357
Ignition System Diagram
357
Ignition System Components Location
357
Diagnostic Information and Procedures
358
Ignition System Symptom Diagnosis
358
No Spark or Poor Spark
359
Repair Instructions
360
Ignition Coil / Plug Cap and Spark Plug Cap
360
Removal and Installation
360
Ignition Coil Removal and Installation
361
Spark Plug Removal and Installation
362
Spark Plug Inspection and Cleaning
362
Ignition Coil / Plug Cap / Ignition Coil Inspection
362
CKP Sensor Inspection
365
CKP Sensor Removal and Installation
366
Engine Stop Switch Inspection
366
Ignition Switch Inspection
366
Ignition Switch Removal and Installation
366
Specifications
367
Service Data
367
Tightening Torque Specifications
367
Special Tools and Equipment
367
Special Tool
367
Starting System
368
Schematic and Routing Diagram
368
Starting System Diagram
368
Component Location
368
Starting System Components Location
368
Diagnostic Information and Procedures
368
Starting System Symptom Diagnosis
368
Starter Motor will Not Run
369
Starter Motor Runs but Does Not Crank the Engine
369
Repair Instructions
370
Starter Motor Components
370
Starter Motor Removal and Installation
371
Starter Motor Disassembly and Assembly
372
Starter Motor Inspection
373
Starter Relay Removal and Installation
374
Starter Relay Inspection
374
Turn Signal / Side-Stand Relay Removal and Installation
375
Side-Stand / Ignition Interlock System Parts Inspection
375
Starter Torque Limiter / Starter Clutch Removal and Installation
378
Starter Torque Limiter Inspection
379
Starter Clutch Inspection
380
Starter Button Inspection
380
Specifications
381
Service Data
381
Tightening Torque Specifications
381
Special Tools and Equipment
382
Recommended Service Material
382
Special Tool
382
Charging System
383
Schematic and Routing Diagram
383
Charging System Diagram
383
Component Location
383
Charging System Components Location
383
Diagnostic Information and Procedures
383
Charging System Symptom Diagnosis
383
Battery Runs down Quickly
384
Repair Instructions
385
Battery Current Leakage Inspection
385
Regulated Voltage Inspection
385
Generator Inspection
386
Generator Removal and Installation
387
Regulator / Rectifier Inspection
389
Battery Components
390
Battery Charging
390
Battery / Battery Holder Removal and Installation
392
Battery Visual Inspection
394
Specifications
395
Service Data
395
Tightening Torque Specifications
395
Special Tools and Equipment
395
Recommended Service Material
395
Special Tool
395
Exhaust System
396
Precautions
396
Precautions for Exhaust System
396
General Description
396
Exhaust Control System Description
396
Exhaust Control System Operation
396
Repair Instructions
397
Exhaust Control System Construction
397
Exhaust System Components
398
EXCVA / EXCV Cable Removal and Installation
399
EXCVA Inspection
402
EXCVA Pulley / EXCV Cable Inspection
402
EXCVA Adjustment
402
Exhaust Pipe / Muffler Removal and Installation
404
Exhaust System Inspection
407
EXCV Inspection
407
Specifications
408
Service Data
408
Tightening Torque Specifications
408
Special Tools and Equipment
408
Recommended Service Material
408
Special Tool
408
Precautions
410
Precautions for Suspension
410
Suspension General Diagnosis
411
Diagnostic Information and Procedures
411
Suspension and Wheel Symptom Diagnosis
411
Front Suspension
412
Repair Instructions
412
Front Fork Components
412
Front Fork Removal and Installation
413
Front Fork Disassembly and Assembly
414
Front Fork Inspection
414
Front Fork Parts Inspection
419
Specifications
420
Service Data
420
Tightening Torque Specifications
420
Special Tools and Equipment
421
Recommended Service Material
421
Special Tool
421
Rear Suspension
422
Repair Instructions
422
Rear Suspension Components
422
Rear Suspension Assembly Construction
423
Rear Shock Absorber Removal and Installation
424
Rear Suspension Inspection
424
Rear Shock Absorber Inspection
425
Rear Suspension Adjustment
425
Rear Shock Absorber Disposal
425
Swingarm / Cushion Lever Removal and Installation
426
Cushion Lever / Cushion Rod Inspection
428
Cushion Lever / Cushion Rod Bearing Removal and Installation
429
Swingarm Related Parts Inspection
431
Swingarm Bearing Removal and Installation
432
Specifications
433
Service Data
433
Tightening Torque Specifications
433
Special Tools and Equipment
434
Recommended Service Material
434
Special Tool
434
Wheels and Tires
435
Precautions
435
Precautions for Wheel and Tire
435
Repair Instructions
436
Front Wheel Components
436
Front Wheel Assembly Construction
437
Front Wheel Assembly Removal and Installation
438
Front Wheel Related Parts Inspection
440
Front Wheel Dust Seal / Bearing Removal and Installation
441
Rear Wheel Components
443
Rear Wheel Assembly Construction
444
Rear Wheel Assembly Removal and Installation
445
Rear Wheel Related Parts Inspection
446
Rear Wheel Dust Seal / Bearing Removal and Installation
448
Tire Removal and Installation
449
Wheel / Tire / Air Valve Inspection and Cleaning
451
Air Valve Removal and Installation
451
Wheel Balance Check and Adjustment
452
Specifications
453
Service Data
453
Tightening Torque Specifications
453
Special Tools and Equipment
454
Recommended Service Material
454
Special Tool
454
Precautions
458
Precautions for Driveline / Axle
458
Drive Chain / Drive Train / Drive Shaft
459
Diagnostic Information and Procedures
459
Drive Chain and Sprocket Symptom Diagnosis
459
Repair Instructions
460
Secondary Gear Components
460
Secondary Gear Construction
461
Secondary Driven Gear Assembly Removal and Installation
461
Secondary Driven Gear Disassembly and Assembly
462
Secondary Driven Gear Related Parts Inspection
467
Secondary Gear Shim Inspection and Adjustment
468
Final Bevel Gear Components
470
Final Gear Construction
471
Final Gear Assembly Removal and Installation
471
Final Gear Disassembly and Assembly
472
Final Gear Parts Inspection
479
Universal Joint Removal and Installation
480
Universal Joint Inspection
481
Rear Wheel Dumper Removal and Installation
481
Wheel Dumper Inspection
482
Final Gear Shim Inspection and Adjustment
482
Specifications
486
Service Data
486
Tightening Torque Specifications
486
Special Tools and Equipment
487
Recommended Service Material
487
Special Tool
487
Precautions
492
Precautions for Brake System
492
Brake Fluid Information
492
Brake Control System and Diagnosis
493
Schematic and Routing Diagram
493
Front Brake Hose Routing Diagram
493
Rear Brake Hose Routing Diagram
494
Diagnostic Information and Procedures
495
Brake Symptom Diagnosis
495
Repair Instructions
496
Brake Pedal Height Inspection and Adjustment
496
Front Brake Light Switch Inspection
496
Rear Brake Light Switch Inspection
496
Rear Brake Light Switch Inspection and Adjustment
496
Brake Fluid Level Check
497
Brake Hose Inspection
497
Air Bleeding from Brake Fluid Circuit
497
Brake Fluid Replacement
498
Front Brake Hose Removal and Installation
500
Rear Brake Hose Removal and Installation
500
Front Brake Master Cylinder Components
501
Front Brake Master Cylinder Assembly Removal and Installation
502
Front Brake Master Cylinder / Brake Lever Disassembly and Assembly
503
Front Brake Master Cylinder Parts Inspection
504
Rear Brake Master Cylinder Components
505
Rear Brake Master Cylinder Removal and Installation
506
Rear Brake Master Cylinder Disassembly and Assembly
508
Rear Brake Master Cylinder Parts Inspection
509
Service Data
510
Tightening Torque Specifications
510
Special Tools and Equipment
511
Recommended Service Material
511
Special Tool
511
Front Brakes
512
Repair Instructions
512
Front Brake Components
512
Front Brake Pad Inspection
513
Front Brake Pad Replacement
513
Front Brake Caliper Removal and Installation
514
Front Brake Caliper Disassembly and Assembly
515
Front Brake Caliper Parts Inspection
518
Front Brake Disc Removal and Installation
519
Front Brake Disc Inspection
519
Service Data
520
Tightening Torque Specifications
520
Special Tools and Equipment
521
Recommended Service Material
521
Special Tool
521
Rear Brakes
522
Repair Instructions
522
Rear Brake Components
522
Rear Brake Pad Inspection
523
Rear Brake Pad Replacement
523
Rear Brake Caliper Removal and Installation
524
Rear Brake Caliper Disassembly and Assembly
525
Rear Brake Caliper Parts Inspection
526
Rear Brake Disc Removal and Installation
528
Rear Brake Disc Inspection
528
Specifications
529
Service Data
529
Tightening Torque Specifications
529
Special Tools and Equipment
530
Recommended Service Material
530
Special Tool
530
Precautions
532
Precautions for Transmission / Transaxle
532
Manual Transmission
533
Diagnostic Information and Procedures
533
Manual Transmission Symptom Diagnosis
533
Repair Instructions
534
Transmission Components
534
Transmission Removal
535
Transmission Installation
536
Transmission Construction
539
Countershaft Gear / Driveshaft Gear Disassembly and Assembly
540
Transmission Related Parts Inspection
543
Gear Position (GP) Switch Inspection
544
Gear Position (GP) Switch Removal and Installation
544
Gearshift Lever Construction
545
Gearshift Lever Removal and Installation
546
Gearshift Lever Height Inspection and Adjustment
546
Gearshift Shaft / Gearshift Cam Plate Components
547
Gearshift Shaft / Gearshift Cam Plate Removal and Installation
547
Gearshift Linkage Inspection
550
Gearshift Shaft Oil Seal / Bearing Removal and Installation
551
Specifications
552
Service Data
552
Tightening Torque Specifications
552
Special Tools and Equipment
553
Recommended Service Material
553
Special Tool
553
Clutch
554
Precautions
554
Precautions for Clutch System
554
Schematic and Routing Diagram
554
Clutch Cable Routing Diagram
554
Diagnostic Information and Procedures
554
Clutch System Symptom Diagnosis
554
Repair Instructions
555
Clutch Lever Position Switch Inspection
555
Clutch Cable Removal and Installation
555
Clutch Components
556
Clutch Removal
557
Clutch Installation
559
Primary Driven Gear Removal and Installation
562
Clutch Parts Inspection
563
Specifications
565
Service Data
565
Tightening Torque Specifications
565
Special Tools and Equipment
566
Recommended Service Material
566
Special Tool
566
Precautions
568
Precautions for Steering
568
Steering General Diagnosis
569
Diagnostic Information and Procedures
569
Steering Symptom Diagnosis
569
Steering / Handlebar
570
Repair Instructions
570
Handlebars Components
570
Handlebars Removal and Installation
571
Handlebars Inspection
573
Steering Components
573
Steering Removal and Installation
574
Steering Related Parts Inspection
576
Steering System Inspection
577
Steering Stem Bearing Removal and Installation
577
Steering Tension Adjustment
578
Specifications
578
Tightening Torque Specifications
578
Special Tools and Equipment
579
Recommended Service Material
579
Special Tool
579
Precautions
583
Precautions for Electrical System
583
Component Location
583
Electrical Components Location
583
Wiring Systems
584
Schematic and Routing Diagram
584
Wiring Diagram
584
Wiring Harness Routing Diagram
590
Specifications
592
Service Data
592
Lighting Systems
593
Repair Instructions
593
Headlight Components
593
Headlight Removal and Installation
594
Headlight Bulb Replacement
594
Headlight Beam Adjustment
595
Headlight Relay Inspection
595
Rear Combination Light Components
596
Rear Combination Light Removal and Installation
596
License Plate Light Components
597
License Plate Light Removal and Installation
597
License Plate Light Bulb Replacement
598
Turn Signal Light Components
598
Front Turn Signal Light Removal and Installation
599
Rear Turn Signal Light Removal and Installation
599
Turn Signal Light Bulb Replacement
600
Turn Signal / Side-Stand Relay Inspection
600
Turn Signal / Side-Stand Relay Removal and Installation
600
Hazard Switch Inspection
600
Turn Signal Switch Inspection
601
Passing Light Switch Inspection
601
Dimmer Switch Inspection
602
Specifications
602
Service Data
602
Special Tools and Equipment
602
Special Tool
602
Combination Meter / Fuel Meter / Horn
603
General Description
603
Combination Meter System Description
603
Repair Instructions
604
Combination Meter Components
604
Combination Meter Removal and Installation
604
Combination Meter Disassembly and Assembly
604
Combination Meter Inspection
605
Engine Coolant Temperature Indicator Light Inspection
606
Engine Coolant Temperature Removal and Installation
606
Fuel Level Indicator Inspection
606
Fuel Level Indicator Switch (Thermistor) Inspection
607
Fuel Level Gauge Inspection
608
Speedometer Inspection
608
Speed Sensor Removal and Installation
608
Speed Sensor Inspection
609
Oil Pressure Indicator Inspection
610
Oil Pressure Switch Removal and Installation
610
Ignition Switch Inspection
610
Ignition Switch Removal and Installation
610
Horn Inspection
611
Horn Removal and Installation
611
Specifications
612
Service Data
612
Tightening Torque Specifications
612
Special Tools and Equipment
612
Recommended Service Material
612
Special Tool
612
Exterior Parts
613
Exterior Parts Construction
613
Fastener Removal and Installation
614
Exterior Parts Removal and Installation
615
Specifications
618
Tightening Torque Specifications
618
Special Tools and Equipment
618
Recommended Service Material
618
Body Structure
619
Repair Instructions
619
Body Frame Construction
619
Steering Lock Bracket Construction
620
Front Footrest Bracket Construction
620
Side-Stand Construction
621
Side-Stand Removal and Installation
621
Specifications
622
Tightening Torque Specifications
622
Special Tools and Equipment
622
Recommended Service Material
622
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