The newly designed single overhead camshaft (SOHC) head was constructed from premium-quality materials, using precise construction and tolerances to deliver leading performance for longer periods.

The reworked transmission has the same ratios as the previous model, but features an improved shifting mechanism for slicker shifting at all times. Made from high-quality steel and treated with a special coating to ensure high durability and reliability, essential for long-distance rallies.

The state-of-the-art Keihin engine management system (EMS) features a new 44 mm throttle body, for instant response and consistent performance due to its unique injector position. ECU maps were adapted for the new airbox and cylinder head, with an improved map-sensor seal. Different maps ensure optimal power delivery for each gear according to information received by the gear sensor. A reworked throttle cable mount allows smoother cable routing and better access.

A new AKRAPOVIČ exhaust is tuned to work perfectly with the new engine and airbox. Compared to its predecessor it is shorter and sits lower for better mass centralisation, which further improves handling.

The completely reworked new airbox is mounted above the engine, ensuring better airflow to the engine for ideal performance and instant throttle response. The large TWIN-AIR filter offers effective protection of the intake from dirt and dust. In addition, the new design provides much more space for electric components like the battery, which is now located in a central area between steering head and airbox, further improving mass centralization.

KTM 450 RALLY REPLICA features a new high-tech and lightweight trellis frame made of chrome-moly steel. The new frame design guarantees optimized stiffness, thus providing better feedback to the rider as well as improved handling and excellent straight-line stability. The rear self-supporting fuel tank with a capacity of 16 litres doubles as the subframe too.

The new model features a cast aluminum swingarm that is lighter and has precisely-tuned flex behavior that supports the suspension action. A reworked linkage system with a revised rising rate transfers force to a new shock absorber, which gives the rider an improved feel, better traction and increased bottoming resistance - for better stability and safety when in full flight.

The new KTM 450 RALLY REPLICA is fitted with the latest WP PRO COMPONENTS suspension. Up front, a 48 mm closed cartridge XACT PRO fork features sophisticated Cone Valve technology, which combines with the new WP XACT PRO shock in the rear for improved overall damping, balanced responsiveness and higher bottoming resistance to keep things stable at race pace. These fully-adjustable components can be fine-tuned precisely to suit the rider and terrain.

Between the rider and race bike lies a newly shaped seat. It provides improved ergonomics, increased grip and heightened control, while boasting better seat comfort for longer distance race action.

With direct input from KTM's factory racers, the new bodywork was designed and shaped to keep the bike as slim as possible. The aim was perfect ergonomics and contact points for the rider, with more freedom of movement. A newly-developed navigation tower made of extra-light carbon fiber is well protected behind the new fairing for significantly improved aerodynamics that drastically decrease turbulent wind forces around the rider's head in a seated riding position. All of this translates to less stress and fatigue.