KTM reveal 2025 450 Rally Replica
While they’ve been bettered by Honda and GasGas in recent years, KTM remains the most successful manufacturer in the annual Dakar Rally. That success has spawned an annual ‘Rally Replica’ edition for two decades, starting with the big 660cc singles and switching to 450cc when that capacity limit was introduced for Dakar in 2011. Recently, KTM unveiled the 2025 version of their popular 450 Rally Replica.
Described as the most updated version of this high-spec, limited-edition model in the past five years, the 2025 450 Rally Replica features major changes to the engine, cooling system, frame and bodywork. Developed by KTM Factory Racing, the MY25 bike is said to be the closest ever to the factory racing machine.
The SOHC 450cc single is fitted with a newly designed cylinder head, along with “a feast of high-end hardware”, like an Akrapovic exhaust system, to provide what KTM claim is unmatched power and reliability. ECU settings are rally-specific, fuel-injection has been updated and a lightweight li-Ion battery for the electric starter is standard.
The radiator is now made up of two separate units, providing more cooling power, along with redundancy if one gets damaged. There’s also a reinforced clutch and strengthened gearbox.
The frame for the 2025 bike is new, assembled from laser-cut, hydro-formed sections and hand-welded in the KTM Motorsports facility. Compared to the previous steel trellis frame, revised longitudinal and torsional flex parameters provide what KTM says is exceptional rider feedback, energy absorption and straight-line stability.
At the tail end, there’s a new die-cast aluminum swingarm that’s hollow, designed to offer optimal stiffness and reliability at the lowest possible weight.
Excel alloy rims remain, matched to aluminium hubs via lightweight spokes, while the braking is made up of 300mm front and 240mm rear discs, with a Brembo two-piston floating caliper up front and single-piston caliper at the rear.
Fuel capacity of 34.5 litres is split across 9.0- and 9.5-litre tanks up front, and a 16-litre tank at the rear that doubles as the subframe. A pair of separate fuel pumps can be activated independently and draw fuel from either the front or rear tanks.
Suspension is made up of the latest WP PRO components, with a fully-adjustable 48mm WP XACT PRO 7548 fork in new clamps for optimal stiffness. The upper clamp now includes a handling damping system that’s been developed in-house and fitted with a Scotts steering damper. At the rear, a WP XACT PRO 7750 shock is the same as that used by the KTM factory riders and is also fully adjustable.
A major styling update for the 2025 450 Rally Replica has resulted in a sharper, more aggressive profile. The new-look plastics are still white, but graphics have been revised. Tank placement has been improved and the radiator shrouds redesigned, while the rally-specific seat is said to deliver improved ergonomics and comfort over long distances.
A new tower for the digital road book is made from carbon fibre and sits behind a redesigned fairing that provides significantly better aerodynamics, according to KTM. The reshaped fairing also protects an all-new, lighter and narrower dashboard with integrated warning lights.
There’s a new LED headlight system, with overall lighting output increased by 33 per cent.
Finally, the 2025 450 Rally Replica introduces a unique space for tools, integrated into the engine cover. More convenient than having tool rolls strapped to the bike or having to carry them in your bumbag, this gives riders quick access to what they need, when they need it.
Only 100 units of the 2025 KTM 450 Rally Replica will be produced for global sale. As previous years’ replicas have been snapped up soon after release, the entire 2025 allocation has most likely been accounted for by the time you read this. Australian pricing has not been revealed, but would be at least $50,000, based on past editions.
See your KTM dealer for details.
