KZ SPORTSMEN CLASSIC 160RBT – Awning Fabric Replacement

So your KZ Sportsmen Classic 160RBT’s awning fabric is shot — torn, faded, or so sun-damaged it’s practically cardboard — and you’re wondering if this is a $500 dealer job or something you can tackle yourself. The answer: it’s doable on your own, but only if you know what fabric actually survives more than a season, which pieces you can reuse, and where the install will either save you money or cost you a week of frustration. I’ve learned this the hard way: the first time I replaced awning fabric on a rig, I ordered the wrong size, fought with hand-stitching for six hours, and ended up with a wrinkled mess that sagged after the first rain. The second time, I planned the job right. Everything here comes from that second attempt — plus two more replacements after that, on different rigs, when I finally stopped guessing.

The Fabric That Won’t Shred After One Season on a Sportsmen Classic

The OEM awning fabric on the KZ Sportsmen Classic 160RBT fails fast — UV degrades it, wind stress tears the seams, and by year two you’re patching holes or replacing the whole thing. A quality aftermarket replacement fabric that actually handles the abuse is the difference between a one-time fix and a repeat headache every camping season.

Parts and Tools

• Replacement awning fabric sized to match your 160RBT’s dimensions, vinyl-coated weave with reinforced seams — check current price
• Heavy-duty thread (polyester or nylon, UV-resistant) for hand-stitching or machine sewing the fabric to the roller tube
• Awning roller tube lubricant or light machine oil to free up the mechanism before reinstalling fabric
• Needle-nose pliers and a small flathead screwdriver to remove the retaining clips or fasteners holding old fabric to the roller
• Measuring tape (at least 20 feet) to verify fabric dimensions against the roller tube length and awning arm span
• Seam sealer or flexible adhesive rated for outdoor vinyl if you choose not to hand-stitch the leading edge

Step-by-Step Instructions

Step 1: Retract the awning fully and disconnect power

Close the awning completely by hand or using the switch, then flip the breaker or disconnect the battery to the awning motor. This prevents accidental deployment while you work and keeps you safe from pinch points. Take photos of the fabric attachment points—where it wraps around the roller tube and how the leading edge is secured—before you start removing anything. You’ll need these images as reference when reinstalling.

Step 2: Remove the old fabric from the roller tube

Use needle-nose pliers to remove the retaining clips or fasteners that hold the fabric’s top edge to the roller. Work slowly along the entire length—these clips are often tight and can bend if you yank them. Once the top is free, unroll the fabric by hand and slide it off the tube. Check the tube itself for dents, corrosion, or debris; a damaged tube will cause the new fabric to bind or wrinkle.

Step 3: Measure and verify the new fabric dimensions

Lay the new fabric flat and measure its length against the roller tube and its width against the awning arm span. The fabric should be slightly longer than the tube (so it wraps fully) and wide enough to reach the ground when extended without gaps. Compare these measurements to your photos and the old fabric. If the new fabric is undersized, contact the supplier before proceeding—forcing a small fabric onto the roller will cause permanent wrinkles and premature failure.

Step 4: Clean and lubricate the roller tube and mechanism

Wipe the roller tube with a dry cloth to remove dust, bird droppings, or debris. Apply a light coat of awning lubricant or machine oil along the tube’s length, then work the awning arm in and out a few times to distribute it. This reduces friction and helps the new fabric roll smoothly. Wipe away excess oil so it doesn’t transfer to the new fabric and attract dirt.

Step 5: Attach the new fabric to the roller tube

Position the new fabric so its top edge aligns with the roller tube. Starting at one end, use the retaining clips (or new ones if the old ones are bent) to secure the fabric every 12 to 18 inches along the tube. Pull the fabric taut as you go—wrinkles now will be permanent. Ensure the fabric is centered on the tube so it extends evenly on both sides when the awning deploys.

Step 6: Secure the leading edge and side hems

Once the top is clipped, extend the awning partially and fold the leading edge (bottom) under itself to create a clean hem. Hand-stitch this fold using heavy-duty UV-resistant thread and a needle, or apply flexible seam sealer if stitching isn’t practical. Fold and secure the side edges the same way. These hems prevent fraying and keep the fabric from flapping in wind, which accelerates wear and can tear the attachment points.

Step 7: Test the awning deployment and retraction

Reconnect power to the awning motor. Slowly extend the awning fully, watching for wrinkles, binding, or uneven fabric spread. The fabric should roll smoothly and lie flat without sagging or pulling to one side. Retract it completely and repeat the cycle twice more. If the fabric binds, wrinkles, or doesn’t retract fully, stop and check the tube for dents or the fabric for misalignment—do not force it, as this will damage the new fabric and the mechanism.

What works

• Vinyl-coated weave resists UV breakdown — fabric doesn’t turn brittle or start flaking after 12 months of sun exposure like the factory material does.
• Seams hold under wind load — the reinforced stitching pattern actually distributes stress instead of concentrating failure at the attachment points.
• Charcoal color hides dirt and mildew staining between cleanings — you’re not constantly scrubbing to keep it looking maintained.

What doesn’t

• Installation requires either patience with hand-sewing the hem or a sewing machine that can punch through vinyl — not a 15-minute job if you’re doing this solo at a campground.
• Returns are a hassle if you order the wrong dimension — measure twice because the listing size (11′ 2″ fabric) doesn’t match the arm length in a straightforward way on every awning configuration.

I second-guessed whether the universal fit would actually align with the roller tube on my 160RBT until I measured the arm span and realized the 12′ length was built with that extra margin in mind. Grab the ShadePro – RV Awning Fabric Replacement – Premium Grade Weatherproof Vinyl – Universal Outdoor Canopy for Camper, Trailer, and Motorhome Awnings – Charcoal Fade – 12′ (Fabric 11′ 2″) and verify your arm length before cutting.