Had a similiar problem ..
with Andreas and my new Shoei's. Feckin hated them after we bought them.
Just before we went to Lake Garda, I decided to treat us both to new helmets, and being a Shoei fan (saved my bonce when I stacked at Mallory), we looked around and tried on literally dozens before settling on two new Shoei Raids.
By the time we had got home and gone out for a blast on the following day, Andrea was in tears with the pain in the side of her head, and with me being a specy wearer, found that after about 20 mins, I had incredible pain around my ears.
For the trip to Garda, I ditched my Shoei and wore my old Lazer flip up, probably the best choice I made given the appalling weather, they don't mist at all, but Andrea was stuck with her Shoei. So she was poppin asprin for the trip, and we were stopping every 40 minutes for a helmet break. The trip was a nightmare for her.
Once back from Garda we took both lids back and asked for them to be either replaced or a refund, shop didn't want to know. Said they were damaged! I'd only worn mine for about 2 hours!
So we had two Raids that we were not wanting to wear again, so I took a stanley knife to the inside of mine and cut two grooves in the inner lining for my glasses' arms, much better now, and I've "shaved" an area of the inner lining from where it was causing pain from Andreas'. They are better now, but I shouldn't have to start carving the things up.
How the hell is someone supposed to know what a helmet, (or even a bike for that matter), is going to be like after 6 hours or more when you only get to try them on in a shop for a couple of minutes?
I want to replace my Suzuki V-Strom asap, but when Andrea sits on any other bike, she says "yes, very nice, but what is it like after 3 hours?" and very few dealers let you have a long test ride. Ideally a whole weekend would be a perfect test, but you try getting one.
Dunno :dunno: what the solution is, but I get a bit pissed at being required to buy without a test, wouldnt buy a car without trying it would we? :bang:
mike