2025 KTM 450 Rally Replica arrives with major updates to engine, chassis and styling in what the Austrian manufacturer is calling their biggest update since 2020 of the hand-built customer rally bikes.

The accolade of “most successful motorcycle in Dakar Rally history” is nothing to be sniffed at. Sure, we know about the race wins by the Pro riders but from Malle Moto/Originals class to the rank and file privateers, KTM are correct to say the 450 rally replica is the go-to machine for rally.

The big news for all those riders interested in a new one is the 2025 450 Rally Replica has undergone its most major update since 2020 with upgrades to the engine and gearbox, sharper bodywork, new fuel tanks and “refined” chassis all developed by KTM Factory Racing.

The reworked 450cc fuel-injection motor, in essence the same as found in the motocross and enduro models, has a new SOHC cylinder head, a reinforced clutch, and a strengthened gearbox.

Two separate radiators now take care of cooling instead of the previous single unit to ensure more cooling, reliability and efficiency for the engine.

One of the things making the 450 Rally special is a hand-welded frame from 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 KTM say.

This is supported by a new hollow, die-cast aluminium swingarm with tweaked stiffness character and improved reliability.

The rear, self-supporting 16-litre fuel tank doubles as the subframe and joins the two additional 9 and 9.5-liter tanks up front. These are fed by two separate fuel pumps which can be activated independently via a handlebar switch.

This pushes the total fuel-carrying capacity of the 2025 KTM 450 Rally Replica to approximately 34.5 litres (7.5 Gal) for the longest rally stages.

The 2025 KTM 450 Rally Replica is fitted with 48mm WP XACT PRO 7548 closed cartridge cone valved forks clamped into new 23mm offset, CNC machined triple clamps. The upper clamp also boasts an in-house developed PHDS (bump absorption) system, fitted with a SCOTTS steering damper.

A WP XACT PRO 7750 shock absorber is also fully adjustable for individual set up of rider and specific terrain.

Fresh look

Visually, the 2025 KTM 450 Rally Replica has undergone a major styling update. A sharper, and more aggressive profile features a new navigation tower made of extra-light carbon fibre behind an improved fairing, which KTM say significantly improves aerodynamics for 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 too, 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 pretty cool space for tools integrated into the sump guard or lower engine cover. This gives riders quick access to wrenches and frees up additional space and weight on the rider.

As ever, the new KTM 450 Rally Replica is the only motorcycle completely produced and assembled in the KTM Motorsports building in Austria which you can buy. But equally, with only 100 units being made available snooze and you lose.

Orders open April 24, 2024. Visit your nearest KTM dealer to order. Price not known at time of writing.

More information: www.KTM.com  

Photo Credit: Marco Campelli