@othalan,
When I fly I have 2 bags only.
A Enduristan Tornado 50L duffel bag is checked in together with my helmet in a nondescript brown box. Hand carrying a helmet on board Air Asia is a hit & miss thing. Airport security might not allow the helmet on board as carry on.
The Enduristan duffel and the helmet box comes in to about 17 to 18kg. I typically buy about 20kg on luggage.
The other 40L duffel bag is carry on and has my textile jacket & pants with the armour and my other stuff like phone charger, power bank, secondary phone for navigation, passport, etc.
I will leave my nondescript helmet box in a hotel and pick it up when I return the bike.
Your comment on buying a helmet locally sounds like a good idea for further thought. I don't have to faff with bringing my own helmet.
In fact whenever I fly overseas and bring my helmet, I have to go to the airport customs at my home city to declare the helmet and they will provide me with a little slip which is a temporary import document. If I don't have that document I will have to pay tax when entering Malaysia again as Customs will scan the bags and if they see a helmet they assume that the helmet was purchased overseas.
My next planned trip is Sumatra, Indonesia so I will gather more information on buying a cheap helmet there.
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