KTM has been the dominant force in motorcycle rallying since the turn of the century, with 19 Dakar wins since 2001. The production version of its factory rally bike, the KTM 450 Rally Replica, enters a new generation in 2025.
Changes for the 2024 450 Rally Replica extend from the powertrain into the chassis and make this about as much of a generation change as it’s possible to get.
Obviously, the motor is still a 450cc single, and it’s derived from the motor used in the 450 SX-F motocross bike and 450 EXC-F enduro bike. For 2025, the motor incorporates a new cylinder head (still with a SOHC layout), a reinforced clutch, and a strengthened gearbox. Also, the single radiator is replaced with a dual radiator layout on the new bike.
The frame has a guard towards the rear and down towards the engine mounts. It’s still steel like you might expect, and still orange-anodised under that cover - similarly predictable. The sections are laser-cut and hydro-formed, and the whole thing is hand-welded in the KTM Motorsports facility in Mattighofen.
“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 says.
There is no subframe bolted to the back, at least not in the traditional sense. On the ‘25 Rally Replica, KTM uses a new self-supporting 16-litre fuel tank to double as the subframe. In combination with two up-front tanks - one nine litres, the other 9.5 litres - the new bike manages a total fuel capacity of 34.5 litres.
A new, hollow, die-cast aluminium swingarm works in conjunction with a WP Xact Pro 7750 rear shock, while the front end is suspended by a 48mm WP Xact Pro 7548 closed cartridge cone valved fork, clamped into a new 23mm offset CNC-machined triple clamp. There’s also a Scotts steering damper.
Ergonomically, of course, a lot of the cockpit is taken up by the navigation tower, but this is now positioned behind a redesigned fairing, intended to improve aerodynamics to reduce buffeting. The dashboard itself is narrower and lighter, while a new LED headlight improves lighting output by a claimed 33 per cent.
Only 100 2025 KTM 450 Rally Replicas will be built, and you will only find out the price when you turn up at a KTM dealer and ask very nicely for them to let you buy one. Orders open on 24 April.
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