Ooohh Trevor, I'm cringing at the thought of how your engine was working.
My worst experience happened in 1991 after I changed the M21 engine in the outfit to a B33 motor.
The sidevalver was very slow for long distance hauls so I bought a second hand B33 engine and decided to replace every moving part before introducing it to the sidecar.
Well, the first long run was to the Dutch BSA International Rally and as I was working in London at the time, the initial running in period was an extremely long two day journey from my home in NE England down to the smoke. After a week at work, my wife joined me and we set off for Sheerness and the ferry to Vlissingen, loaded to the the brim for a two week camping holiday.
As we came off the ferry the following morning there was a peculiar noise coming from the engine and after running some checks I found that this noise disappeared when I retarded the engine slightly. Off we go for the remaining 125 mile trip and after a while the noise was getting appreciably worse. Even on full retard it was still there. Enough's enough and we called it a day and arranged to get hauled to the rally by trailer for the final 25 miles. Yeah, it was final. The brand new big end bearing had failed miserably and it was the days before breakdown cover was popular.
Well, a complete stripdown showed that the centre pin on the bigend had never been hardened and this was the cause of the problem. So I called home and arranged to have the original bigend bearing shipped over to the rally site at Nijmegen and the engine was completely rebuilt over the following five days. The hardest part was finding a workshop with the facilities to enable me to split the flywheels and then line them up again after the replacement item was fitted. Everything else was done in (or just outside) the tent.
That was a challenge and even though I've experienced some problems during my biking career I reckon that that was the worst thing that happened to me on a BSA.
Oh!! The joys of motoring eh!!
Beezageezauk.