KTM has just unveiled their new 450 Rally Replica, the customer version of its factory rally machine. Holding the accolade as the most successful motorcycle in Dakar Rally history, the bike is derived on feedback from KTM’s Dakar winners, featuring components that provide the performance level directly requested by these rally raid champions. 

For 2025, KTM says the 450 Rally Replica boasts its most extensive refresh to date featuring a new powerplant, bodywork revisions, and a refined chassis developed by KTM Factory Racing. This is the only customer-facing motorcycle completely produced and assembled in the KTM Motorsports building in Austria, with only 100 units being made available to rally racers around the globe.

At its heart sits a reworked version of the championship 450cc fuel-injection motor found in the KTM Motocross and Enduro stables. Fitted with a newly-designed SOHC cylinder head, a reinforced clutch, and a strengthened gearbox, it is a feast of high-end hardware engineered to deliver optimal power and reliability. Two separate radiators take care of cooling instead of the previous single unit for better cooling power and efficiency for the engine.

The 2025 model now also boasts a new frame which is welded by hand in the KTM Motorsports production facility. Assembled from laser-cut, hydro-formed sections, the frame features specifically calculated longitudinal and torsional flex parameters compared to the previous steel trellis frame construction but maintains exceptional rider feedback, energy absorption, and straight-line stability. This is supported by a new hollow, die-cast aluminum swingarm designed to offer optimal stiffness and reliability at the lowest possible weight.

At the rear, a self-supporting 16-liter fuel tank doubles as the subframe with two additional 9 and 9.5-liter tanks up front, driven by two separate fuel pumps which can be activated independently from either the front, or the rear tanks. This pushes the total fuel-carrying capacity of the 2025 KTM 450 Rally Replica to approximately 34.5 liters (9.1 gallons).

From a handling perspective, the new 450 Rally Replica is fitted with the latest WP PRO components. In the front, 48 mm WP XACT PRO 7548 closed-cartridge cone valve forks with 304mm (12 inches) of travel are clamped into a new 23 mm offset, CNC machined triple clamps for optimal stiffness. The upper clamp also boasts an in-house developed PHDS system, fitted with a SCOTTS steering damper.

Taking charge at the rear is the WP XACT PRO 7750 shock offering 280 mm (11 inches) of suspension travel. Fully customizable for individual set up of rider and specific terrain. Tried, tested and used in multiple Rally stage wins by the likes of Kevin Benavides and Matthias Walkner.

Visually, the new 450 Rally Replica has undergone a styling update, with a sharper, more aggressive profile. A specifically developed navigation tower made of extra-light carbon fiber sits behind an improved fairing, which provides even better aerodynamics. This means riders experience less turbulence and buffeting while in a seated riding position.

The fairing also protects an all-new, lighter, narrower dashboard, with integrated warning lights and mountings for a digital roadbook system. A new LED headlight system is now incorporated into the front mask, increasing overall lighting output by 33%, which plays a vital role in the early morning stage starts or late-night arrivals.

The 2025 KTM 450 Rally Replica also features a well-thought-through and unique space for tools integrated into the engine cover. This gives riders quick access to wrenches and frees up additional space and weight on the rider’s person.

Availability and Price

The KTM 450 Rally Replica is a highly sought-after machine, limited to only 100 units worldwide. And they go fast! KTM’s announcement didn’t confirm pricing but previous models had a price tag of EUR 25,900 ($27,220 USD) plus VAT & shipping. Orders open on April 24, 2024 at authorized KTM dealers. For more information visit ktm.com.

2025 KTM 450 Rally Replica Specs

Photo by M. Campelli