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

The reworked transmission has the exact same ratios as the Dakar Rally championship winning machines of the Red Bull KTM Factory Racing team. It features an improved shifting mechanism for slicker shifting at all times. It is made from high-quality steel and is treated with a special coating to ensure high durability and reliability, things that are essential for long-distance rallies.

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

The AKRAPOVIČ exhaust is tuned to work perfectly with the updated engine and airbox. The silencer is short and sits low for better mass centralisation, which further improves handling.

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

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

The 2021 model features a cast aluminum swingarm that is ultra light and has precisely-tuned flex behavior that supports the suspension action. The linkage system with a well-considered rising rate transfers force to the fully adjustable shock absorber, which gives the rider great feel, ideal traction and optimal bottoming resistance - for better stability and safety when in full flight.

The 2021 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 slim yet comfortable seat. It provides good ergonomics, optimum grip and heightened control, while boasting seat comfort for longer distance race action.

With direct input from KTM's factory racers, the bodywork has been 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. Designed for competition, the navigation tower is made of extra-light carbon fiber is well protected behind the fairing for perfect 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.