A revised crank web should also help with balance while reducing engine vibration and improving low rpm throttle response. Cooling capacity in the engine was increased with a new water jacket routing and larger radiators with new louvers. The new louvers are now smaller with a shallower angle to flow more air and now feature four blades instead of three.
To reduce weight engine oil volume was lowered to 1.3L and a KX450F-type crankcase oil filter was added to maintain reliability. Kawasaki says transmission durability was boosted with a bigger interval between the gear shafts, which allows for the use of stronger gears.

Kawasaki reduced the fork off-set by 1mm, enlarged the wraparound tube guards and reshaped and stiffened the upper triple clamp.

The green plastic shrouds and have a longer lasting finish and few graphics to wear off.
Kawasaki switched to a new ratchet-drive shift mechanism and integrated the clutch cable into the crankcase to improve shifting and clutch lever feel. Lever ratios, spring rates and shaft locations were also revised.
The slimmer feel of the 2009 KX250F is partially due to its new aluminum perimeter frame and sub-frame. This new frame uses fewer parts and gussets and is 2.2 lbs lighter than the 2008 model. The main frame spars were reshaped and provide a 6mm narrower overall profile at the rider’s knees. A new manufacturing process and down-tube design shed weight and work with relocated engine mounts to improve rigidity balance.
A new aluminum swingarm works in conjunction with the frame revisions and pivots from a higher position on the frame for a claimed improvement in traction. It is a now a lighter, more tapered design with a ‘D’ profile and new cross bracket. Mounting the suspension arm of the Uni-Trak rear suspension system below the swingarm resulted in a longer rear suspension stroke and more precise tuning.
A new rear Showa shock with a large 50mm piston diameter, which features a Kashima Coat on the shock internals, has damping characteristics that Kawasaki says offers better response and improved bottoming performance.
Included in the Showa fork upgrades is a Lites-class first: titanium-coated slider tubes. This dark navy blue coating decreases stiction and provides a super-hard surface to help prevent scratches and damage to the tubes. Also, the inner surface of the outer fork tubes has a friction-reducing Kashima Coat treatment.
To optimize rigidity balance Kawasaki reshaped and stiffened the upper triple clamp and reshaped and decreased the rigidity of the outer fork tubes. Other fork enhancements include a 1mm reduction in fork off-set, revised suspension settings and enlarged wraparound tube guards.
A larger, resin skid plate and narrower, longer lasting chain-guide offer greater protection without adding extra weight. The one-piece, dual injected, two-tone black and green plastic shrouds and side number plates have a longer lasting finish and few graphics to wear off.