WR250R changes from '11 to '12
October 27, 2011 version
A part is assumed to be changed if the part number for '12 is changed from the '11 part number. However, a part number can be unchanged, but the part is actually changed. Case in point - the fuel pump assembly. Replacement fuel pump assemblies have the same assembly part number, but an inspection of the assembly shows the pump motor has a different part number on it, and the fuel pump performs differently (riders report hearing a stronger sounding motor).
The parts are shown in order by section. For each changed part, the '11 part is shown first, followed by the '12 part.
There are 134 parts changes from '11 to '12: 4 are cosmetic (decals), 112 are mechanical/electrical, and 18 are in the engine/tranny. In my opinion, the changes are minor, but check the list to see for yourself.
This year, many of the changes seem very minor such as these (count of occurrences is shown in either '11 or '12 part description):
BAND 10
BOLT 34
CLAMP 11
COLLAR 6
NUT 8
SCREW 24
WASHER 7
I have not tried to determine the effects or extent of these and other minor changes. For some parts, I have added a note where I think I know what's going on with the change.
| Ref No | Part Number | Description | Qty | Notes |
| AIR INDUCTION SYSTEM | ||||
| 8 8 | 90467-17089-00 90467-17128-00 | CLIP CLIP | 1 1 | '11 '12 |
| CAMSHAFT CHAIN | ||||
| 10 10 | 3D7-12210-10-00 3D7-12210-11-00 | TENSIONER ASSY, CAM CHAIN TENSIONER ASSY, CAM CHAIN | 1 1 | '11 '12 ALERT, redesigned for reliability |
| 16 16 | 90110-06168-00 91312-06014-00 | BOLT, HEXAGON SOCKET HEAD BOLT | 2 2 | '11 '12 |
| 18 18 | 90110-06168-00 91312-06014-00 | BOLT, HEXAGON SOCKET HEAD BOLT | 2 2 | '11 '12 |
| CLUTCH | ||||
| 13 13 | 92902-06200-00 92990-06200-00 | WASHER WASHER, PLAIN | 1 1 | '11 '12 |
| 14 14 | 95302-06600-00 95380-06600-00 | NUT NUT | 1 1 | '11 '12 |
| CRANKCASE | ||||
| 4 4 | 93210-06422-00 93210-06632-00 | O-RING O-RING | 1 1 | '11 '12 |
| 5 5 | 90110-06182-00 91317-06012-00 | BOLT, HEXAGON SOCKET HEAD BOLT | 1 1 | '11 '12 |
| 8 8 | 90105-06081-00 95022-06012-00 | BOLT, FLANGE BOLT, FLANGE | 2 2 | '11 '12 |
| 10 10 | 90105-06081-00 95022-06012-00 | BOLT, FLANGE BOLT, FLANGE | 2 2 | '11 '12 |
| 15 15 | 91312-06090-00 91314-06090-00 | BOLT BOLT | 2 2 | '11 '12 |
| CRANKCASE COVER 1 | ||||
| 16 16 | 90149-06083-00 90149-06084-00 | SCREW SCREW | 2 2 | '11 '12 |
| 29 29 | 93210-16716-00 93210-16772-00 | O-RING O-RING | 2 2 | '11 '12 |
| CRANKSHAFT & PISTON | ||||
| 17 17 | 90149-06069-00 90149-06068-00 | SCREW SCREW | 3 3 | '11 '12 |
| 20 20 | 90282-05013-00 90282-05065-00 | KEY, STRAIGHT KEY, STRAIGHT | 1 1 | '11 '12 ALERT, redesigned for reliability |
| CYLINDER | ||||
| 9 9 | 90430-08119-00 90201-08087-00 | GASKET WASHER, PLATE | 1 1 | '11 '12 |
| 17 17 | 90110-06175-00 91314-06020-00 | BOLT, HEXAGON SOCKET HEAD BOLT | 5 5 | '11 '12 |
| 24 24 | 99530-08016-00 91808-16023-00 | PIN, DOWEL PIN, DOWEL | 2 2 | '11 '12 Redesigned for reliability |
| ELECTRICAL 1 | ||||
| 6 6 | 97702-50514-00 97780-50514-00 | SCREW, TAPPING SCREW, TAPPING | 2 2 | '11 '12 |
| 20 20 | 95602-05200-00 95607-05200-00 | NUT, SELF-LOCKING NUT, U FLANGE | 2 2 | '11 '12 |
| ELECTRICAL 2 | ||||
| 7 7 | 3L8-82131-01-00 22F-82131-00-00 | BAND, BATTERY BAND, BATTERY | 1 1 | '11 '12 |
| 11 11 | 32D-82511-09-00 90890-56028-00 | KEY, MAIN SWITCH KEY, BLANK (5SJ1) | 1 1 | '11 '12 Don't have a clue |
| 12 12 | 90109-08195-00 90109-08196-00 | BOLT BOLT | 2 2 | '11 '12 |
| 15 15 | 5JJ-82151-10-00 67F-82151-50-00 | FUSE (15A-BL) FUSE (15A) | 2 2 | '11 '12 |
| 16 16 | 5JJ-82151-30-00 67F-82151-40-00 | FUSE (10A-BL) FUSE (10A) | 2 2 | '11 '12 |
| 17 17 | 90465-10098-00 80L-26397-00-00 | CLAMP CLAMP | 1 1 | '11 '12 |
| 18 18 | 90464-13073-00 90464-15195-00 | CLAMP CLAMP | 1 1 | '11 '12 |
| 20 20 | 90464-16061-00 1UA-82591-00-00 | CLAMP BAND | 1 1 | '11 '12 |
| 27 27 | 90464-16061-00 1UA-82591-00-00 | CLAMP BAND | 1 1 | '11 '12 |
| 35 35 | 90157-05025-00 98580-05014-00 | SCREW, PAN HEAD SCREW, PAN HEAD | 2 2 | '11 '12 |
| 37 37 | 90464-16061-00 1UA-82591-00-00 | CLAMP BAND | 3 3 | '11 '12 |
| 39 39 | 90464-16061-00 1UA-82591-00-00 | CLAMP BAND | 2 2 | '11 '12 |
| 45 45 | 90464-16061-00 1UA-82591-00-00 | CLAMP BAND | 1 1 | '11 '12 |
| 48 48 | 90105-06048-00 95817-06012-00 | BOLT, FLANGE BOLT, FLANGE | 1 1 | '11 '12 |
| EXHAUST | ||||
| 9 9 | 95824-08035-00 95814-08035-00 | BOLT, FLANGE BOLT, FLANGE | 1 1 | '11 '12 |
| 18 18 | 92902-10200-00 92990-10200-00 | WASHER WASHER, PLAIN | 2 2 | '11 '12 |
| 24 24 | 90387-063E6-00 90387-06388-00 | COLLAR COLLAR | 2 2 | '11 '12 |
| 26 26 | 3D7-14708-00-P0 3D7-14708-10-P0 | PROTECTOR ASSY PROTECTOR ASSY | 1 1 | '11 '12 |
| FENDER | ||||
| 4 4 | 90480-13398-00 90480-13014-00 | GROMMET GROMMET | 2 2 | '11 '12 |
| 17 17 | 97702-50014-00 97707-50014-00 | SCREW, TAPPING SCREW, TAPPING | 2 2 | '11 '12 |
| FRAME | ||||
| 11 11 | 90105-10244-00 90105-10245-00 | BOLT, FLANGE BOLT, FLANGE | 2 2 | '11 '12 |
| 17 17 | 90179-10658-00 95704-10500-00 | NUT NUT, FLANGE (95701-10500-00) | 3 3 | '11 '12 |
| 19 19 | 90149-10031-00 90149-10033-00 | SCREW SCREW | 4 4 | '11 '12 |
| 29 29 | 90111-08072-00 92017-08014-00 | BOLT, HEX. SOCKET BUTTON BOLT, BUTTON HEAD | 2 2 | '11 '12 |
| 33 33 | 95022-08040-00 95024-08040-00 | BOLT, FLANGE BOLT, FLANGE | 1 1 | '11 '12 |
| 38 38 | 95022-08040-00 95024-08040-00 | BOLT, FLANGE BOLT, FLANGE | 1 1 | '11 '12 |
| 45 45 | 90151-06067-00 90151-06068-00 | SCREW, COUNTERSUNK SCREW, COUNTERSUNK | 1 1 | '11 '12 |
| 48 48 | 90464-16061-00 1UA-82591-00-00 | CLAMP BAND | 1 1 | '11 '12 |
| 51 51 | 90465-10098-00 80L-26397-00-00 | CLAMP CLAMP | 2 2 | '11 '12 |
| 66 66 | 90464-16061-00 1UA-82591-00-00 | CLAMP BAND | 1 1 | '11 '12 |
| 70 70 | 120-82131-00-00 7H3-82131-00-00 | BAND, BATTERY BAND, BATTERY | 1 1 | '11 '12 |
| 74 74 | 90464-16061-00 1UA-82591-00-00 | CLAMP BAND | 2 2 | '11 '12 |
| FRONT BRAKE CALIPER | ||||
| 2 2 | 90149-06001-00 90149-06228-00 | SCREW SCREW | 6 6 | '11 '12 |
| 7 7 | 1UY-25825-51-00 36Y-W0048-00-00 | CAP BLEED SCREW KIT | 1 1 | '11 '12 |
| 8 8 | 1UY-25824-51-00 36Y-W0048-00-00 | SCREW, BLEED BLEED SCREW KIT | 1 1 | '11 '12 |
| FRONT FORK | ||||
| 22 22 | 95022-08040-00 95024-08040-00 | BOLT, FLANGE BOLT, FLANGE | 2 2 | '11 '12 |
| 45 45 | 95022-08040-00 95024-08040-00 | BOLT, FLANGE BOLT, FLANGE | 2 2 | '11 '12 |
| 48 48 | 95022-08040-00 95024-08040-00 | BOLT, FLANGE BOLT, FLANGE | 4 4 | '11 '12 |
| FRONT MASTER CYLINDER | ||||
| 10 10 | 97007-06025-00 97017-06025-00 | BOLT BOLT | 2 2 | '11 '12 |
| 18 18 | 95607-06100-00 95617-06100-00 | NUT, U NUT, U | 1 1 | '11 '12 |
| FRONT WHEEL | ||||
| 10 10 | 90480-08608-00 90480-10068-00 | GROMMET GROMMET | 1 1 | '11 '12 |
| FUEL TANK | ||||
| 2 2 | 3D7-24602-00-00 3D7-24602-20-00 | CAP ASSY CAP ASSY | 1 1 | '11 '12 Redesigned for reliability |
| 6 6 | 90149-06022-00 90149-06302-00 | SCREW SCREW | 1 1 | '11 '12 |
| 7 7 | 90387-061U9-00 90387-087L0-00 | COLLAR COLLAR | 1 1 | '11 '12 |
| 12 12 | 90111-06090-00 90111-06095-00 | BOLT, HEX. SOCKET BUTTON BOLT,HEX. SOCKET BUTTON | 2 2 | '11 '12 |
| 13 13 | 90387-061U9-00 90387-087L0-00 | COLLAR COLLAR | 2 2 | '11 '12 |
| GENERATOR | ||||
| 3 3 | 90110-06169-00 91317-06025-00 | BOLT, HEXAGON SOCKET HEAD BOLT | 3 3 | '11 '12 |
| 5 5 | 90110-06168-00 91312-06014-00 | BOLT, HEXAGON SOCKET HEAD BOLT | 2 2 | '11 '12 |
| HANDLE SWITCH & LEVER | ||||
| 7 7 | 95607-06100-00 95617-06100-00 | NUT, U NUT, U | 1 1 | '11 '12 |
| 8 8 | 3D7-82917-00-00 3C5-82917-00-00 | SWITCH SWITCH | 1 1 | '11 '12 Redesigned for reliability |
| 14 14 | 98507-05030-00 98517-05030-00 | SCREW, PAN HEAD SCREW, PAN HEAD | 2 2 | '11 '12 |
| HEADLIGHT | ||||
| 14 14 | 341-84331-60-00 90157-04001-00 | SCREW, RIM ADJUSTING SCREW, PAN HEAD | 2 2 | '11 '12 |
| 15 15 | 92902-04600-00 92990-04600-00 | WASHER, PLATE WASHER, PLATE | 2 2 | '11 '12 |
| INTAKE | ||||
| 6 6 | 3D7-14452-00-00 51Y-14462-00-00 | SEAL SEAL | 1 1 | '11 '12 |
| 7 7 | 97702-50025-00 97707-50025-00 | SCREW, TAPPING SCREW, TAPPING | 9 9 | '11 '12 |
| 31 31 | 99002-04600-00 99080-04600-00 | CIRCLIP E-CLIP | 2 2 | '11 '12 |
| 32 32 | 90450-54005-00 90450-54009-00 | HOSE CLAMP ASSY HOSE CLAMP ASSY | 1 1 | '11 '12 |
| 46 46 | 97707-50020-00 90167-05078-00 | SCREW, TAPPING SCREW, TAPPING | 1 1 | '11 '12 |
| 50 50 | 97702-50020-00 90167-05078-00 | SCREW, TAPPING SCREW, TAPPING | 1 1 | '11 '12 |
| 51 51 | 95822-06020-00 95817-06020-00 | BOLT, FLANGE BOLT, FLANGE | 3 3 | '11 '12 |
| 54 54 | 95822-06025-00 95817-06025-00 | BOLT, FLANGE BOLT, FLANGE | 1 1 | '11 '12 |
| INTAKE 2 | ||||
| 5 5 | 98507-06012-00 98517-06012-00 | SCREW, PAN HEAD SCREW, PAN HEAD | 2 2 | '11 '12 |
| OIL CLEANER | ||||
| 1 1 | 5D3-13440-00-00 5D3-13440-09-00 | ELEMENT ASSY, OIL CLEANER ELEMENT ASSY, OIL CL | 1 1 | '11 '12 ALERT, redesigned for reliability |
| OIL PUMP | ||||
| 3 3 | 91312-06030-00 90110-06138-00 | BOLT BOLT, HEXAGON SOCKET HEAD | 2 2 | '11 '12 |
| 7 7 | 90110-06173-00 90110-06172-00 | BOLT, HEXAGON SOCKET HEAD BOLT, HEXAGON SOCKET HEAD | 2 2 | '11 '12 |
| 9 9 | 90149-06082-00 90149-06081-00 | SCREW SCREW | 1 1 | '11 '12 |
| 10 10 | 93210-06564-00 93210-07540-00 | O-RING O-RING | 1 1 | '11 '12 |
| 11 11 | 93210-09754-00 93210-09350-00 | O-RING O-RING | 2 2 | '11 '12 |
| RADIATOR & HOSE | ||||
| 5 5 | 90450-25037-00 90450-22M14-00 | HOSE CLAMP ASSY HOSE CLAMP ASSY | 5 5 | '11 '12 Redesigned for reliability |
| 6 6 | 90450-28014-00 90450-28001-00 | HOSE CLAMP ASSY HOSE CLAMP ASSY | 1 1 | '11 '12 Redesigned for reliability |
| 16 16 | 95702-06500-00 95780-06500-00 | NUT, FLANGE NUT, FLANGE | 1 1 | '11 '12 |
| 24 24 | 90149-06302-00 90149-06105-00 | SCREW SCREW | 2 2 | '11 '12 |
| 25 25 | 90105-06690-00 95817-06016-00 | BOLT, FLANGE BOLT, FLANGE | 2 2 | '11 '12 |
| REAR ARM | ||||
| 12 12 | 90387-06513-00 90387-060N3-00 | COLLAR COLLAR | 2 2 | '11 '12 |
| REAR BRAKE CALIPER | ||||
| 2 2 | 90149-06001-00 90149-06228-00 | SCREW SCREW | 6 6 | '11 '12 |
| 7 7 | 1UY-W0048-50-00 36Y-W0048-00-00 | BLEED SCREW KIT BLEED SCREW KIT | 1 1 | '11 '12 |
| REAR MASTER CYLINDER | ||||
| 12 12 | 90111-06092-00 90111-06059-00 | BOLT, HEX. SOCKET BUTTON BOLT, HEXAGON SOCKET BUTTON | 2 2 | '11 '12 |
| REAR WHEEL | ||||
| 3 3 | 93306-27205-00 93306-27206-00 | BEARING BEARING | 1 1 | '11 '12 Redesigned for reliability |
| 10 10 | 94212-18230-00 94241-18153-00 | TUBE (120/80-18 M/C TR4) TUBE (4.10-18) | 1 1 | '11 '12 |
| 12 12 | 90480-08608-00 90480-10068-00 | GROMMET GROMMET | 2 2 | '11 '12 |
| 15 15 | 95602-08200-00 90185-08169-00 | NUT, SELF-LOCKING NUT, SELF-LOCKING | 6 6 | '11 '12 |
| SHIFT SHAFT | ||||
| 1 1 | 1D7-18127-00-00 5VK-18127-00-00 | STOPPER, SCREW STOPPER, SCREW | 1 1 | '11 '12 Redesigned for reliability |
| 11 11 | 93102-12106-00 93102-12321-00 | OIL SEAL (SD 12-22-5 HS) OIL SEAL (SD 12-22-5 HS) | 1 1 | '11 '12 Redesigned for reliability |
| 14 14 | 91312-08020-00 91314-08020-00 | BOLT BOLT | 1 1 | '11 '12 |
| SIDE COVER | ||||
| 3 3 | 90201-06058-00 90201-06020-00 | WASHER, PLATE WASHER, PLATE | 1 1 | '11 '12 |
| 11 | 32C-2174G-00-00 | GRAPHIC, 3 | 1 | '11 Part removed |
| 12 | 32C-2174H-00-00 | GRAPHIC, 4 | 1 | '11 Part removed |
| 18 16 | 98902-06010-00 98980-06010-00 | SCREW, BIND SCREW, BIND | 1 1 | '11 '12 |
| 19 17 | 90387-066R8-00 90387-062M9-00 | COLLAR COLLAR | 1 1 | '11 '12 |
| 24 22 | 98902-06010-00 98980-06010-00 | SCREW, BIND SCREW, BIND | 1 1 | '11 '12 |
| 25 23 | 90387-066R8-00 90387-062M9-00 | COLLAR COLLAR | 1 1 | '11 '12 |
| 30 28 | 32C-2137N-50-00 32C-2137N-70-00 | GRAPHIC 1 GRAPHIC 1 | 1 1 | '11 '12 BNG |
| 31 29 | 32C-2137P-50-00 32C-2137P-70-00 | GRAPHIC 2 GRAPHIC 2 | 1 1 | '11 '12 BNG |
| STAND FOOTREST | ||||
| 9 9 | 91402-20012-00 91490-20015-00 | PIN, COTTER PIN, COTTER | 1 1 | '11 '12 |
| 13 13 | 91402-25015-00 91490-25020-00 | PIN, COTTER PIN, COTTER | 2 2 | '11 '12 |
| 23 23 | 95612-10100-00 95617-10100-00 | NUT, U NUT, U | 1 1 | '11 '12 |
| 25 25 | 90105-10244-00 90105-10245-00 | BOLT, FLANGE BOLT, FLANGE | 2 2 | '11 '12 |
| 29 29 | 90504-18005-00 90504-18031-00 | SPRING, COMPRESSION SPRING, COMPRESSION | 1 1 | '11 '12 |
| 36 36 | 90504-18005-00 90504-18031-00 | SPRING, COMPRESSION SPRING, COMPRESSION | 1 1 | '11 '12 |
| 39 39 | 90111-08047-00 92012-08020-00 | BOLT, HEX. SOCKET BUTTON BOLT, BUTTON HEAD | 2 2 | '11 '12 |
| STARTER CLUTCH | ||||
| 4 4 | 3LD-15521-00-00 26H-15521-00-00 | SHAFT 1 SHAFT 1 | 1 1 | '11 '12 Redesigned for reliability |
| STARTING MOTOR | ||||
| 6 6 | 1FK-81847-00-00 93210-24235-00 | O-RING O-RING | 1 1 | '11 '12 |
| STEERING | ||||
| 2 2 | 93332-00068-00 93332-00078-00 | BEARING BEARING | 1 1 | '11 '12 Redesigned for reliability |
| 15 15 | 95022-08040-00 95024-08040-00 | BOLT, FLANGE BOLT, FLANGE | 4 4 | '11 '12 |
| STEERING HANDLE & CABLE | ||||
| 7 7 | 98507-05020-00 98517-05020-00 | SCREW, PAN HEAD SCREW, PAN HEAD | 1 1 | '11 '12 |
| TAILLIGHT | ||||
| 4 4 | 90119-06241-00 90119-06242-00 | BOLT, WITH WASHER BOLT, WITH WASHER | 2 2 | '11 '12 |
| 8 8 | 90105-05024-00 90105-05025-00 | BOLT, FLANGE BOLT, FLANGE | 2 2 | '11 '12 |
| 9 9 | 90201-054K4-00 90201-05556-00 | WASHER, PLATE WASHER, PLATE | 2 2 | '11 '12 |
| 12 12 | 97702-50014-00 97707-50014-00 | SCREW, TAPPING SCREW, TAPPING | 2 2 | '11 '12 |
| 14 14 | 4HC-84744-00-00 4SV-84347-00-00 | BULB (12V-5W) BULB (12V-5W) | 1 1 | '11 '12 |
| 17 17 | 90111-05030-00 90111-05010-00 | BOLT, HEX. SOCKET BUTTON BOLT | 2 2 | '11 '12 |
| 20 20 | 90201-05036-00 90201-061A5-00 | WASHER, PLATE WASHER, PLATE | 4 4 | '11 '12 |
| TRANSMISSION | ||||
| 8 8 | 93306-20447-00 93306-20427-00 | BEARING BEARING (62/22-9-C3) | 1 1 | '11 '12 Redesigned for reliability |
| 13 13 | 93410-26067-00 99009-26400-00 | CIRCLIP CIRCLIP | 1 1 | '11 '12 Redesigned for reliability |
| WATER PUMP | ||||
| 7 7 | 90149-06083-00 90149-06084-00 | SCREW SCREW | 2 2 | '11 '12 Redesigned for reliability |