KZ SPORTSMEN CLASSIC 160RBT - Roof Vent Fan Replacement

KZ SPORTSMEN CLASSIC 160RBT – Roof Vent Fan Replacement

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Complete repair guide for the KZ SPORTSMEN CLASSIC 160RBT – Roof Vent Fan Replacement.

Parts & Tools You’ll Need

Step 1: Diagnose Fan Condition and Prepare Workspace

Begin by visually inspecting your existing roof vent fan for signs of failure: listen for grinding noises, check for water leaks around the frame, and test whether the fan blades spin freely when powered on. Turn off power at the 12V breaker before proceeding. You’ll need to remove interior trim panels around the vent opening to assess the mounting flange condition and check for any water damage or mold growth inside the vent housing. Document the current fan model and wiring configuration with photos, as this will help you choose between the Maxxair 00-05100K or Fan-Tastic Vent 5000R replacement options based on your RV’s existing setup.

Step 2: Remove Old Fan and Clean Mounting Surface

Disconnect the 12V wiring connector from your existing fan by gently pulling the spade terminals apart. Unscrew the four mounting bolts (typically 3/8-inch) that secure the fan housing to the roof, working from inside the RV if accessibility allows. Once the old fan is free, carefully pry away the old Roof Vent Mounting Butyl Seal Tape using a plastic scraper, taking care not to gouge the roof material. Clean the mounting surface thoroughly with a lint-free cloth and mineral spirits to remove all old sealant residue, dirt, and debris, ensuring a clean surface for the new seal tape to adhere properly.

Step 3: Install New Butyl Seal Tape and Fan Flange

Cut the Roof Vent Mounting Butyl Seal Tape into four equal pieces and apply one piece along each edge of the roof opening, pressing firmly to create a complete seal around the perimeter. Position your new fan (whether the Maxxair 00-05100K or Fan-Tastic Vent 5000R) over the opening, ensuring the flange sits flush and square with the roof surface. Insert the four mounting bolts through the fan’s flange holes and thread them into the roof framing until snug, then tighten each bolt in a cross-pattern (similar to tightening car wheel lugs) to a torque specification of 8-10 foot-pounds to ensure even pressure without cracking the plastic housing.

Step 4: Seal Roof Penetration with Dicor Sealant

Apply Dicor 501LSW Lap Sealant around the entire perimeter of the fan flange where it meets the roof, creating a continuous bead approximately 1/4-inch wide. Use a caulking gun held at a 45-degree angle and move steadily along each edge, then smooth the bead with a wet finger to ensure full contact with both the fan flange and roof material. Pay special attention to the corners and any gaps, as these are primary points for water infiltration on travel trailers. Allow the sealant to cure for the full time specified on the Dicor product label (typically 24 hours) before exposing the vent to moisture or weather.

Step 5: Connect 12V Wiring and Install Thermostat Kit

Route the fan’s 12V power wire to your RV’s electrical panel, using the quick-connect 12V Wiring Connector to join it to the existing circuit—if upgrading fans, verify the new fan’s amperage draw doesn’t exceed 10 amps on your existing breaker. If installing the optional Vent Fan Thermostat Kit, connect it between the power source and fan according to kit instructions, typically positioning the temperature sensor near the ceiling vent opening. Secure all wiring with adhesive clips every 12 inches along the roof rafters, keeping wires away from sharp edges and heat sources. Double-check that polarity is correct (positive and negative) before restoring power to the breaker.

Step 6: Install Bug Screen and Interior Trim

Insert the Bug Screen / Insect Guard Insert into the interior opening of the new vent fan, ensuring it seats fully into the retaining clips provided with most replacement fans. The screen should sit flush with the interior vent collar and be secure enough to resist vibration while remaining easy to remove for cleaning. Reinstall any interior trim panels or finish rings around the vent opening, sealing any gaps around the interior flange with paintable caulk if needed to match your RV’s interior finish. Verify that the fan housing sits level and that no gaps exist between the mounting flange and roof surface when viewed from above.

Step 7: Test Fan Operation and Verify Seal Integrity

Turn power back on at the 12V breaker and test the fan in both forward and reverse (if using the reversible Fan-Tastic Vent 5000R model), listening for smooth operation and confirming proper airflow direction. If your new fan includes a thermostat kit, set the temperature threshold and allow the fan to cycle on and off at least once to verify the sensor is responding correctly. Conduct a visual inspection from the roof during light rain or use a garden hose to spray water around the mounted fan, checking for any leaks into the interior cavity or along the seams. Finally, run the fan for 15 minutes continuously and feel for any vibration, noise, or unusual heat generation—silence and smooth operation indicate a successful replacement.