Keystone Arcadia – RV Awning Fabric and Motor Replacement

by

RV Awning Fabric and Motor Replacement

Parts Needed:

Step 1: Awning Assessment and Preparation

Thoroughly inspect your awning to determine the exact repair or replacement needed. Extend the awning fully on a calm day (never work on awnings in windy conditions). Walk around the entire awning examining the fabric for tears, holes, UV damage (fading, brittleness), mildew stains, and seam separation. Small tears under 6 inches can often be repaired with awning repair tape, but larger tears or widespread UV damage necessitate complete fabric replacement. Inspect the awning arms for bends, cracks, or loose attachment points. For electric awnings, test motor operation by extending and retracting several times, listening for grinding, slow operation, or unusual sounds that indicate motor wear or failure. Gather precise measurements for ordering replacement fabric or parts. Measure the awning length from end cap to end cap along the roller tube – this is your fabric length requirement. Also measure the projection (how far the awning extends from the RV) as fabrics come in different projection sizes. Standard projections are typically 8′ or 8’6″ but verify yours. Record the manufacturer and model information from the awning label (usually on the end cap or roller tube). This ensures you order compatible replacement fabric with proper track configuration. For motor replacement, photograph the existing motor, noting mounting configuration, wire connections, and any visible model numbers on the motor housing. Prepare the work area and safety equipment for awning fabric replacement. Position two sturdy ladders on level ground, one at each end of the awning. Ensure both ladders are stable and rated for your weight plus tool weight. Have a helper available throughout the entire process – awning fabric replacement is impossible to safely perform alone due to the length and weight of fabric and roller assembly. Clear the area around the RV of any obstacles. If working on a hot day, schedule work for early morning or evening when metal components won’t be uncomfortably hot to handle. Gather all tools and parts before beginning, including the new fabric, lubricants, and fasteners. Review manufacturer instructions specific to your awning model if available.

Step 2: Removing Old Fabric or Motor

Begin fabric removal by extending the awning approximately 12 inches and securing the support arms. Position your ladders at each end of the partially extended awning. Secure the awning arms in place using the locking mechanism or temporary support (bungee cords or zip ties work well). This prevents unexpected roller movement during fabric removal. Have your helper stationed at one end while you work from the other end. For electric awnings, disconnect power at the breaker or battery to prevent accidental motor activation during the procedure – this is critical for safety as unexpected motor operation could cause injury. Remove the end caps and identify the fabric attachment method. Using appropriate tools, remove the screws securing the end caps to the roller tube (typically 3 screws per end cap). Set these screws aside carefully as you’ll need them for reassembly. Examine how the fabric attaches to the roller tube – most systems use one of two methods: a track system where fabric slides into a groove on the roller tube, or a direct attachment using screws through a fabric bead that slides into the roller tube channel. For track systems, the fabric and valence will be secured with screws at each end. For electric awnings, you’ll need to carefully work around the motor assembly when accessing one end cap. For electric awning motor replacement, safely disconnect and remove the motor unit. Before disconnecting any wires, photograph all connections from multiple angles. Label each wire with tape indicating its position and function. Most awning motors have 2-3 wire connections: power positive (typically red), negative/ground (typically black), and sometimes a control or sensor wire. Disconnect these wires carefully, ensuring you don’t pull on the wire itself but rather on the connector. Locate the motor mounting hardware, typically 3-4 bolts securing the motor housing to the roller tube end. Remove these bolts using an appropriate socket, supporting the motor weight as you remove the final bolt. The motor assembly should slide out from the roller tube end. Note the exact position and orientation of the motor for correct installation of the replacement unit. Remove the old awning fabric from the roller tube. Locate the screws securing the fabric in the roller tube track (typically at each end). Remove these screws and carefully pull the fabric bead out of the track channel. You may need to gently pry the track open slightly using a flat screwdriver to facilitate fabric removal. With your helper’s assistance, carefully pull the old fabric out of the roller track, supporting the fabric as it releases to prevent it from falling. For awnings with a separate valence (the decorative strip hanging from the front), this typically comes out separately from the main fabric. Once the old fabric is free, roll it up for disposal or keep it as a sizing reference. Inspect the roller tube track channel for debris, old sealant, or damage. Clean the channel thoroughly using a rag and mild cleaner, then lubricate with silicone spray to ease installation of new fabric.

Step 3: Installing New Fabric or Motor

Install the replacement motor (if performing motor replacement). Clean the motor mounting area on the roller tube, removing any old grease or debris. Position the new motor at the roller tube end, aligning mounting holes carefully. The motor’s drive gear should engage with the roller tube’s internal mechanism correctly – consult manufacturer instructions for the exact engagement procedure as this varies by awning brand. Insert mounting bolts and hand-tighten them initially. Verify the motor sits flush and square to the roller tube before fully tightening bolts to manufacturer specifications (typically 15-25 ft-lbs). Reconnect all electrical wires following your photos and wire labels: positive to positive terminal, negative to negative, and any control wires to their designated terminals. Ensure all connections are tight and properly insulated. Test motor operation briefly before proceeding with fabric installation to verify correct motor function and proper rotation direction. Prepare and install the new awning fabric onto the roller tube. Unroll the new fabric partially on a clean, flat surface to prevent dirt contamination. Identify the leading edge (typically marked with tape or a label) that will attach to the roller tube. Using a flathead screwdriver, carefully widen the roller tube track channel slightly to ease fabric insertion. Spray silicone lubricant generously into the track channel. With your helper at the opposite end, begin feeding the fabric’s leading bead into the roller tube track. Work slowly and methodically, ensuring the fabric enters the track straight and doesn’t bunch or fold. Push the fabric bead firmly into the track while your helper supports the fabric roll, preventing it from dragging on the ground. Continue feeding fabric into the track until it extends through to the opposite end of the roller tube. Secure the fabric to the roller tube and reinstall the assembly. Once the fabric is fully inserted through the roller tube track, install the screws through the track into the fabric bead at both ends to lock it in place. Position these screws about 2-3 inches from each end. Tighten firmly but don’t overtighten as this can strip the fabric bead material. For awnings with a separate valence, install it in its designated track (usually on the front lower part of the roller tube) using the same technique as the main fabric. With the fabric secured to the roller tube, carefully reinstall the end caps using the original screws, ensuring proper seating and alignment with mounting holes. If the awning was removed from the RV, reinstall the roller tube assembly into the mounting brackets. With your helper’s coordination, lift the fabric-loaded roller tube into position, sliding it into the awning arm assemblies at each end. The tube should slide smoothly into the mounting brackets. Ensure the tube is fully seated before securing. Install any retaining pins, clips, or bolts that secure the roller tube to the awning arms and mounting brackets. For awnings with a permanent track attached to the RV, you’ll need to slide the roller tube’s polycord (the fabric edge) into the track on the RV sidewall. Lubricate this track with silicone spray. Starting at one end, carefully feed the polycord into the track, working across the awning length until the entire polycord is secured in the track. Install polycord screws at strategic points to prevent the fabric from pulling out of the track. Test the awning operation completely before concluding the repair. For manual awnings, slowly extend the awning by releasing the arm tension and pulling down on the pull strap, monitoring fabric alignment on the roller as it extends. The fabric should roll off evenly without wrinkles or bunching to one side. If misalignment occurs, retract and make minor adjustments to fabric position in the roller tube track. For electric awnings, test motor operation by extending the awning in short increments, watching fabric deployment carefully. The awning should extend smoothly and evenly. Fully extend the awning and inspect fabric tension – it should be taut without excessive looseness or over-tension. Retract the awning completely, ensuring smooth roller operation and proper fabric wind-up. The fabric should wrap neatly on the roller without wrinkles or bulges. Repeat several extend-retract cycles to verify consistent operation. Finally, inspect all mounting hardware, brackets, and connections for tightness. Apply silicone sealant around any mounting brackets that penetrate the RV sidewall or roof to prevent water intrusion.