The small plastic thing that may have come off, are those small rollers that are in the side of the helmet visor that rolls down and holds on to the ratchet mechanism. Those rollers are really small wheels and they are clumsly engineered that they can come off after repeated usage. But that doesn't mean it won't work, it will. That creaking sound is most probably caused the by that roller broken and it can't be replaced, if indeed is broken. And you're absolutely right, AIROH's fit is a little snugger than most helmets and you almost feel choked at times after wearing its sometime. My RJays helmet is my favorite even I have the GP500. It has superb field of vision and excellent ventilation. AIROH is tighter, snugger and the fit is where I hate it, way too snug that it restricts my breathing movement. But after repeated usage it seems to be getting in shape.
The dilemmas you faced were faced by me too, too much perspiration in the head, unable to breathe and a sense of vertigo after wearing this helmet first, all due to the wrong size, I should have gone for a bigger size XL and instead opted for L. But it needs time for you to get used to it.
Cheers!
VJ


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