AN ACR WDB FOUND ITSELF OFF OF THE FLT PLAN ROUTING AS ACR DISPATCH HAD NOT PROPERLY UPDATED THE NEW ROUTING.

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OUR DISPATCH AT DFW FILED OUR FLT PLAN FOR US. OUR TRIP WAS FRANKFURT; GERMANY TO DFW. SEVERAL FLT PLANS WERE FILED BECAUSE WE HAD TO RETURN TO THE GATE FOR A MECHANICAL (4 HR DELAY) DIVERSION TO ORD DUE TO CREW LEGALITY PROB. ENTERING CANADIAN AIRSPACE; ATC CLRED US TO ORD VIA NA204 TO YRI FL310; .83 MACH. THAT CONCURRED WITH OUR FULL CLRNC. EVERYTHING OKAY UP TO YRI (COMMON RTE); HOWEVER; THE NON COMMON PORTION HAD CHANGED TO ORD. WE WERE FILED 'YRI DIRECT YMX J553 YOW J546 TO ECK....' THE NEW NON COMMON PORTION THAT CHANGED APR/THU/93 SHOULD BE 'YRI; POLTY; YMS TO ECK....' THEREFORE; WE WERE ABOUT 20 MI TO THE S OF THE CORRECT TRACK (ROUTING). WE WERE IN RADAR CONTACT AND MONTREAL CTR CALLED US ABOUT 80 MI E OF YMX AND INQUIRED AS TO WHERE WE WERE GOING. WE TOLD THEM TO 'YMX' AND THEY SAID YOU SHOULD BE GOING TO 'POLTY' ETC. AFTER THAT THEY TOLD US TO CONTINUE TO YMX. THEY INFORMED US THAT WE WEREN'T THE FIRST ACR FLT TO BE FILED INCORRECTLY THESE LAST COUPLE OF DAYS AND THAT WE SHOULD LET OUR DISPATCH BE MADE AWARE OF THE PROB. WE WILL! HOWEVER; WE NEGLECTED TO VERIFY THE NON COMMON RTE IN THE COMMERCIAL MANUAL WHICH HAD THE CORRECT CLRNC TO ORD. FACTORS: 1) CONFUSION OF WHICH FLT PLAN; BECAUSE 4 OR 5 WERE FILED AT FRA. 2) MECHANICAL PROB CAUSING OUR DEP TO BE DELAYED BY ABOUT 4 HRS. 3) RELYING ON OUR DISPATCH TO FILE CORRECT CLRNC. 4) FMS TOOK OUR FILED CLRNC; EVEN WITH THE NEW DATABASE IN IT. 5) FLC NOT DOUBLECHKING THE COMMERCIAL MANUAL. 6) PLT FATIGUE DUE TO DELAY ON GND.