Home build: KTM to build one hundred 2025 450 Rally Replicas at their Austrian headquarters, orders open now

235 Dakar stage wins and 19 Dakar titles says KTM know what they’re up to when producing the best rally bikes on the market. 

The KTM 450 rally is the most successful motorcycle in the Dakar’s history and the 450 Rally Replica puts amateur riders in the same saddle as the pros.  For 2025, KTM will be making their most significant updates to the model since 2020, producing and assembling all 100 units at the KTM motorsports building in Austria.

Reworked engine and reinforced components

The list of upgrades for the 2025 KTM 450 Rally Replica is headlined by a reworked version of 450cc fuel injection motor that the KTM Factory Racing Team’s have used in their championship-winning Motocross and Enduro campaigns.

A newly designed SOHC cylinder, a reinforced clutch and a strengthened gearbox all add to this new model’s improved performance and durability. The single radiator of models past has been replaced with a twin unit delivering more efficient cooling to the precision tuned engine.

Lighter, stronger frame

The new engine is mounted on a frame that’s hand welded by the Factory Racing team. Each piece of the frame is laser cut and hydro-formed for unrivalled accuracy. The longitudinal and torsional flex parameters are carefully calculated to improve rider feedback, energy absorption and straight-line stability compared to the previous steel trellis construction.

A new hollow die-cast aluminium swing arm has been added to reduce weight and improve the overall stiffness of the bike. 

Stage-winning fuel capacity

The 2025 KTM Rally Replica has a whooping fuel capacity of 34.5 litres. The two forward and single rear tanks feed the engine with two separate pumps that can be activated independently of each other.

The 16-litre rear tank doubles up as the sub frame, whereas the two forward tanks are compact, carrying 9 and 9.5 litres respectively.

Visual improvements & smart tool solutions

Visually, the KTM designers have made some significant changes to the Rally Replica for MY2025. A sharper, more aggressive profile has been used. The navigation tower has been constructed in super lightweight carbon fibre and tucked behind a more aerodynamic high strength plastic fairing.

A lighter, narrower dashboard is installed with integrated warning lights and a mounting for a digital roadbook system comes as standard. The headlight has been replaced with a new LED system that provides 33% more light, vital for those early starts and late finishes. 

Rally enthusiasts will love KTM’s smart use of space when it comes to creating an easily accessible spot for a few essential tools. Just whip back the engine cover and there’s an integrated space for a small tool kit. 

Orders open for delivery in Q4 2024 

KTM will only build 100 units of the 2025 KTM Rally Replica. As an authorised KTM dealer, we can help you place an order, but don’t hang around if you’re serious about getting your hands on one of the serious rallying machines. 

More info here, call our KTM team on +44 (0) 1684 292929 or pop into our showroom in Tewkesbury to discuss an order.