KTM Launches Overhauled 450 Rally Replica Bike For 2025


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. 

KTM Launches Overhauled 450 Rally Replica Bike For 2025
The 2025 model gets an extensive refresh including a new powerplant, frame, radiators, swingarm, revised bodywork and more.

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.

KTM Launches Overhauled 450 Rally Replica Bike For 2025
A reworked SOHC cylinder head, with a reinforced clutch and gearbox, and the latest electronic fuel injection further improve performance.

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.

KTM Launches Overhauled 450 Rally Replica Bike For 2025
The 2025 debuts a new radiator concept, featuring two radiators instead of one for significantly better cooling efficiency. There is also the benefit of having a backup radiator should one get damaged.


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.

KTM Launches Overhauled 450 Rally Replica Bike For 2025
An all-new hydro-formed, laser-cut, and hand-welded frame forms the backbone of the 2025 450 Rally Replica.
KTM Launches Overhauled 450 Rally Replica Bike For 2025
A new hollow, die-cast aluminum swingarm offers 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).

KTM Launches Overhauled 450 Rally Replica Bike For 2025
KTM Launches Overhauled 450 Rally Replica Bike For 2025
Two separate 9 L fuel tanks upfront and a self-supporting 16 L rear fuel tank offer a total fuel volume of 35 liters. The tanks are controlled by two separate fuel pumps, which can be independently accessed and activated.

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.

KTM Unveils Overhauled 450 Rally Replica Bike For 2025
KTM Unveils Overhauled 450 Rally Replica Bike For 2025
All-new 23 mm offset CNC machined triple clamps with a rally specific design offer optimal stiffness and precise handling when charging through the desert.

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.

KTM Unveils Overhauled 450 Rally Replica Bike For 2025
KTM Unveils Overhauled 450 Rally Replica Bike For 2025
An all-new extra-light carbon fiber navigation tower is well protected behind the fairing with a new, narrower dashboard.

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.

KTM Releases Overhauled 450 Rally Replica Bike For 2025
The ultra-light rally-specific titanium Akrapovic exhaust system has a special hydro-formed section on the bottom for maximum ground clearance.
2025 KTM 450 Rally Replica Bike
A new LED headlight system boasts a light output increase of 33%.

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.

KTM Unveils Overhauled 450 Rally Replica Bike For 2025
The 450 Rally Replica features a fully integrated, purpose-built engine cover space for essential tools.

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

ENGINE TYPE: Single-cylinder, 4-stroke, SOHC
DISPLACEMENT: 449.3 cc
COOLING: Liquid cooled
STARTER: Electric starter
BORE x STROKE: 95 mm x 63.4 mm
CLUTCH: Wet multi-disc clutch, hydraulically actuated
COMPRESSION RATIO: 12.6:1
EMS: Kokusan
LUBRICATION: Forced oil lubrication with 2 oil pumps
TRANSMISSION: 6-speed
TANK CAPACITY (APPROX.): 35 l (9.1 gallons)
FRONT BRAKE DISC DIAMETER: 300 mm
REAR BRAKE DISC DIAMETER: 240 mm
CHAIN: 5/8 x 1/4″
REAR SUBFRAME DESIGN: Self-supporting plastic tank
SUSPENSION TRAVEL (FRONT): 304 mm (12 in.)
SUSPENSION TRAVEL (REAR): 280 mm (11 in.)
WHEELS: Spoked EXCEL wheels with aluminum rims and hubs

Photo by M. Campelli





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