Complete repair guide for the KZ SPORTSMEN CLASSIC 160RBT – Awning Fabric Replacement.
Parts & Tools You’ll Need
- ShadePro – RV Awning Fabric Replacement – Premium Grade Weatherproof Vinyl – Universal Outdoor Canopy for Camper, Trailer, and Motorhome Awnings – Charcoal Fade – 12′ (Fabric 11′ 2″) — Carefree Replacement Awning Fabric Roll
- Leaveshade RV Awning Fabric Replacement Motorhome Camper Trailer Awning Fabric Super Heavy Vinyl Coated Polyester 13’3”(Fit for 14′ Awning)- Mountains (Custom Looking) — Dometic Awning Fabric Replacement
- Vinyl Sling Chair Spline Outdoor Patio Long Solid Awning Cord Replacement Fabric Sling Chair Spline Replacement for Outdoor Patio Lawn Garden Pool Furniture(25 ft,3/16″) — Awning Spline Cord (bead seal)
- Carefree (901012MP) Window Awning Pull Strap — Awning End Cap + Pull Strap Kit
- Extra Strength Fabric Protector Spray Prevents Stains and Repels Liquids. SoftClad Guards Furniture, Shoes, Carpet, Upholstery, Suede, Leather, Couch. Safe for Indoor Use. PFAS Free Formula 32oz — Awning Fabric UV Protectant Cleaner
- scottchen PRO Manual RV Awning Rod Opener Easy Reach Telescopic Puller 13-3/4″ to 44-3/4″ Stainless Steel Silver & Black – 1pack — Spring Tension Adjuster / Winder Tool
- Colingmill 2 Pack Camper Awning Latch RV Awning Lock Kit Camper Awning Part Compatible with Sunchaser 8300 Awnings — Travel Lock / Carrier Clips (2 pack)
- DEF 830472P002 RV Awning Arm Slider Catch Kit Compatible with Dometic A&E 8500 9000 (2 Slider Catch) — Awning Arm Slide Bar Replacement
Step 1: Diagnose Awning Fabric Condition
Start by fully extending your KZ Sportsmen Classic 160RBT’s awning and inspecting the fabric for tears, UV damage, water pooling, or mildew growth. Look for separation between the fabric and the spline cord along the roller tube, and check whether the fabric retracts evenly without bunching or binding. Take photos of any damage and measure your awning’s width and projection depth (typically 8-10 feet wide and 7-8 feet extended on this model) to ensure you order the correct replacement fabric size. If the fabric is merely dirty, try cleaning it first with Awning Fabric UV Protectant Cleaner before committing to replacement.
Step 2: Prepare Workspace and Remove Awning
Park your trailer on level ground with the awning fully extended, then disconnect power to electric awning motors if equipped. Locate the Travel Lock / Carrier Clips (2 pack) at both ends of the awning arms and remove them by loosening the mounting bolts with a wrench. Manually or electrically retract the awning fully into its carrier, then locate the end caps at both sides where the awning roller tube meets the RV sidewall. Remove the bolts securing the end caps and slide the entire awning assembly out from the sidewall bracket—you may need a helper for this 40-50 pound assembly.
Step 3: Remove Old Fabric and Spline Cord
Lay the awning assembly on a clean work surface with the fabric facing upward. Using a flathead screwdriver, carefully pry the old awning spline cord (bead seal) out of the groove along the roller tube, working from one end to the other and collecting the cord for disposal. Once the spline cord is removed, the old fabric should pull away freely from the roller tube. Inspect the tube channel for any debris, dirt, or damage and clean it thoroughly with a dry cloth, as residue will prevent the new fabric from seating properly.
Step 4: Install New Awning Fabric Alignment
Unroll your Carefree or Dometic replacement awning fabric and lay it flat beside the roller tube to verify the width matches your trailer’s awning (typically 8 feet for the 160RBT). Position the fabric so the leading edge (the side that extends first) is aligned with the roller tube’s roller mechanism. Begin feeding the fabric into the channel at one end, ensuring it’s centered and lies flat without twists or wrinkles. Keep the fabric taut but not stretched as you work along the tube, and have a helper hold the opposite end to maintain alignment while you secure the first section with the new spline cord.
Step 5: Secure Fabric with Spline Cord Installation
Using the Awning Spline Cord (bead seal) and a spline roller tool, press the cord firmly into the groove on top of the fabric along the entire length of the roller tube. Work in 12-18 inch sections, applying consistent downward pressure to seat the spline fully into the channel—the fabric should be snug but not compressed. Continue this process along the entire tube length, checking periodically that the fabric remains centered and free of wrinkles behind the spline. Once you reach the end, trim any excess spline cord with a utility knife, leaving a clean butt joint where the cord ends meet.
Step 6: Reinstall Awning Assembly and End Caps
Slide the awning assembly back into the sidewall brackets, ensuring the roller tube seats fully into the support arms on both sides. Reinstall the Awning End Cap + Pull Strap Kit on each end, aligning the caps with the mounting holes and torquing bolts to 15-18 foot-pounds to prevent over-tightening, which can crack the end caps. Reattach the Travel Lock / Carrier Clips (2 pack) at both arm positions and tighten securely—these prevent the awning from bouncing while you’re towing. If your model has an electric motor, reconnect the power connector and test the motor function before fully retracting.
Step 7: Test Awning Operation and Make Adjustments
Extend the awning fully and observe that the fabric deploys smoothly without binding, bunching, or pulling to one side. Check that the fabric tension is even along the roller tube and that there are no wrinkles or sagging in the deployed position. Retract the awning slowly and confirm the fabric retracts evenly and rolls up without twisting—if binding occurs, use the Spring Tension Adjuster / Winder Tool to fine-tune the spring tension by adjusting the tension nut one-quarter turn at a time. Deploy and retract the awning 2-3 times to condition the new fabric and ensure all mechanical components operate smoothly before your next trip.