The KTM 450 RALLY REPLICA has played a significant role in securing 10 of those Dakar Rally titles, making it the most successful model in the competition’s history. The bike has become synonymous with Rally Raid Championships.
Review – Key Features – Features & Benefits – Specifications
2025 KTM 450 Rally Replica: DOMINATE THE DUNES.
Introducing the 2025 KTM 450 Rally Replica…
We can say it; the KTM 450 RALLY REPLICA is the most successful machine ever to line up at the Dakar Rally. Not only has it graced the top step at the hands of seasoned pros, but its victories in the hands of privateers are equally impressive. With 10 out of 19 Dakar wins for KTM, and 235 Stage victories, the 2025 KTM 450 RALLY REPLICA remains the closest bike to a factory racer available off a dealership floor.
2025 KTM 450 Rally Replica Totalmotorcycle.com Key Features
THE 2025 KTM 450 RALLY REPLICA BRINGS MAJOR UPDATES TO THE DUNES
With 235 Dakar stage wins and an impressive 19 Dakar titles, it’s clear that KTM has established itself as a dominant force. The KTM 450 RALLY REPLICA has played a significant role in securing 10 of those Dakar Rally titles, making it the most successful model in the competition’s history. The bike has become synonymous with Rally Raid Championships. For 2025, it sets its sights on even more victories, boasting its most extreme refresh to date.
Holding the accolade as the most successful motorcycle in Dakar Rally history. From Dakar Championship titles to Malle Moto privateers, it is the go-to machine when it comes to multi-stage rally racing.
For 2025, the KTM 450 RALLY REPLICA has undergone its most major update since 2020. With a new powerplant, sharper bodywork, and refined chassis developed by KTM Factory Racing, it is the closest version of a production Factory Racing machine there has ever been.
At its heart sits a reworked version of the championship 450 cc 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 unrivaled power and reliability. Two separate radiators take care of cooling instead of the previous single unit. This ensures more cooling power and efficiency for the engine.
These are now mounted to 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, making it capable of dominating the longest rally stages.
From a handling perspective, the 2025 KTM 450 RALLY REPLICA is fitted with the latest WP PRO COMPONENTS. In the front, 48 mm WP XACT PRO 7548 closed cartridge cone valved fork is clamped into a new 23 mm offset, CNC machined triple clamps ensuring 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. 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 2025 KTM 450 RALLY REPLICA has undergone a major 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 significantly improved 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 riders person.
The 2025 KTM 450 RALLY REPLICA 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 ambitious rally racers around the globe.
Orders open on 24 April 2024.
2025 KTM 450 Rally Replica Totalmotorcycle.com Features and Benefits
Adjustability
At this level, pin-point accuracy in your setup is essential to gaining an edge on the competition. Good thing then, that the 2025 KTM 450 RALLY REPLICA has that covered, with fully adjustable WP Pro Components suspension which can be fine-tuned to the likes and weights of riders and all kinds of varying terrains, as well as adjustable handlebars.
Digital Roadbook
Already compulsory at many races for the Car, SSV, and Truck categories, the 2025 KTM 450 RALLY REPLICA has provisions to allow for the fitment of a digital roadbook. Not only has this new addition undergone many racing kilometers of hard testing, but it is also more accurate, more user-friendly, and brings more functionality to the racing stage. Prefer the old ways? The conventional paper roadbook system still comes in the buy-pack.
All White Plastics
READY TO RACE bikes need racing stickers. While a simple sticker graphic kit for the all-white bodywork comes in the by-pack of the 2025 KTM 450 RALLY REPLICA, the plastics are left untouched for you to design your kit, with your team, sponsor, and individual needs.
LED Headlight
A new LED headlight system is incorporated into the front mask of the 2025 KTM 450 RALLY REPLICA, with an overall light output increase of 33%. Not only does this light the way to the bivouac on those longer stages, but also plays a vital role in the early morning starts and misty weather conditions.
Engine Management System
The EMS and 44 mm throttle body are supplied by Keihin, and have proven to be the best combination for the KTM 450 RALLY REPLICA and feature rally-specific ECU mappings to the airbox, engine, and exhaust combination.
Engine
The powerplant responsible for 10 Dakar victories is based on the hugely successful KTM SOHC 450 cc 4-stroke engine. Engineered with long, hard, and fast rally stages in mind, it features more efficient performance throughout the rev range. For 2025, it is fitted with a newly designed SOHC cylinder head, with a reinforced clutch and gearbox, and the latest electronic fuel injection. The result is unrivaled power, speed, and outstanding reliability.
Cylinder Head
A reworked SOHC cylinder head features newly shaped ports for further improved performance. The single overhead camshaft activates four ultra-lightweight titanium valves via extremely rigid, DLC coasted rocker arms for maximam reliability.
Radiator
The 2025 KTM 450 RALLY REPLICA debuts a new radiator concept. Featuring two independent radiators instead of one, it dramatically improves cooling efficiency. There is also the added benefit of having a backup radiator should one get damaged.
Akrapovič Exhaust
Fitted with a rally-specific titanium Akrapovič exhaust system as standard, the 2025 KTM 450 RALLY REPLICA is ready to roar – with tuning to match. It has a special hydro-formed section on the bottom for maximum ground clearance and boasts ultra-lightweight construction and unmatched performance.
Maximum stability
Triple Clamps
An all-new 23 mm offset CNC machined triple clamps with a rally-specific design ensures optimal stiffness and precise handling when charging through the desert. This, together with an in-house developed PHDS system and the proven SCOTT’s steering damper, provides the confidence to keep it pinned in the faster, flowing rally stages.
Bodywork
Sharper, sleeker, and ready to take on the roughest rally stages, the 2025 KTM 450 RALLY REPLICA has undergone a complete refresh. Redesigned fairings, a new tank layout, and a rally-specific seat provide improved ergonomics and seat comfort over longer distances. This means enhanced rider ergonomics, allowing for perfect control when standing by providing ample grip surfaces and freedom of movement.
Navigation Tower
An all-new navigation tower made of extra-light carbon fiber is well-protected behind the fairing with a new, narrower dashboard. This brings significantly improved aerodynamics, reduced turbulence, and less stress for the rider when blasting across the landscape at maximum speed. Warning lights are now also fully integrated and illuminate when the front or rear tank reserve is activated.
Fuel Tanks
The 2025 KTM 450 RALLY REPLICA boasts a total fuel volume of 35 liters. It has two separate 9-liter fuel tanks upfront and a self-supporting 16-liter fuel tank at the rear. These are controlled by two separate fuel pumps, which can be independently accessed and activated to supply fuel from either the front or the rear fuel tank. This works as a backup system and an additional means to monitor fuel levels.
The backbone
Frame
An all-new hydro-formed, laser-cut, and hand-welded frame forms the backbone of the 2025 KTM 450 RALLY REPLICA. Constructed with precisely calculated parameters of longitudinal and torsional flex, the frame provides exceptional rider feedback, energy absorption, and straight-line stability – all of which are crucial for rally racing. To achieve this, the rotating mass, forged steering head connection, and most of the frame tubes have been completely re-positioned., along with the tube wall thickness, for maximum reliability and specific rigidity in high-stress areas. The frame is finished with a long-lasting and eye-catching powder coating, while the rear self-supporting 16-liter fuel tank doubles as the subframe.
Swingarm
A new hollow, die-cast aluminum swingarm is designed for optimal stiffness and reliability at the lowest possible weight. The topology has also been optimized for optimal rigidity. This works together with a proven linkage system and fully adjustable shock absorber, which gives the rider confidence to go flat out. This also means maximum traction when accelerating and bottoming-out resistance for better stability and safety.
Suspension
The 2025 KTM 450 RALLY REPLICA is fitted with the latest WP PRO COMPONENTS at both ends. In front, a 48 mm WP XACT PRO 7548 closed cartridge fork featuring sophisticated Cone Valve technology shines with outstanding damping performance. A fully adjustable WP XACT PRO 7750 shock takes care of the business in the rear. The suspension components provide full adjustability, improved damping, and higher bottoming reserves for ultimate stability.
Start easy, everytime
E-starter and Battery
A reliable electric starter and lightweight Li-Ion 4.5 Ah battery handle start procedures on the 2025 KTM 450 RALLY REPLICA. Weighing substantially less than a conventional lead battery, the Li-Ion battery delivers reliable power to the electronics, as well as enuring the convenience of easy starting particularly at low temperatures.
Tool Kit Space
The 2025 KTM 450 RALLY REPLICA features a fully integrated and well-thought-out tool storage solution, with an engine cover integrated space for essential tools. This means racers can rest assured that they have what they need out in the dunes should the worst-case scenario occur while freeing up space in your bumbag.
Wheels
Black high-strength alloy rims from EXCEL are coupled to cast aluminum hubs using lightweight spokes and steel nipples for maximum stability and durability. This combination has proven to be the best solution for intense rally racing across all terrain types.
Brakes
Brembo components guarantee total performance and reliability in braking. 300 mm front and 240 mm rear discs deliver superior stopping power, rider feel, and overall control, instilling maximum confidence in any condition.
2025 KTM 450 Rally Replica – Totalmotorcycle.com International Specifications/Technical Details
US MSRP Price: $ See Dealer for pricing in USD
Canada MSRP Price: $ See Dealer for pricing in CDN
Europe/UK MSRP Price: £ See Dealer for pricing in GBP (On The Road inc 20% Vat)
Engine
Transmission 6-speed
Cooling Liquid cooled
Starter Electric starter
Stroke 63.4mm
Bore 95mm
Clutch Wet multi-disc clutch, hydraulically actuated
Compression ratio 12.6
Displacement 449.3cm³
EMS Kokusan
Design 1-cylinder, 4-stroke engine
Lubrication Forced oil lubrication with 2 oil pumps
Chassis
Tank capacity (approx.) 35l
Front brake disc diameter 300mm
Rear brake disc diameter 240mm
Chain 5/8 x 1/4″
Rear subframe design Self-supporting plastic tank
Suspension travel (front) 304mm
Suspension travel (rear) 280mm
Wheels Spoked wheels with aluminium rims
Manufacturer Specifications and appearance are subject to change without prior notice on Total Motorcycle (TMW).
