Great stuff, Alex, great stuff!
I just arrived with my bike in KL via the KLIA airport. I did the whole customs clearance process in a single day incl. building my bike together and being in KL in the afternoon.
1. Before you go to the Cargo-terminal itself you need a day pass in this building
here - 2nd floor and hard to miss due to huge signs. You'll be leaving your passport there. Be sure to take a copy of it with you if your airball hasn't got one attached.
2. Go to the
Cargo Terminal or in Openstreetmaps called KLIA3 and show your day pass.
3. Pick up your original airbill
here. The guards at the gate were kind enough to organise a transport for me to that building. If you've got a backpack with you, you can leave it at the customer service right next door.
4. Pick up your customs-report-prepartation-stuff
here, they'll give you an offices name. It's Core 2 now, and not Core 1 as stated on their plan. Second to last door on the left in the 2nd floor.
5. Go back with that and pay about 50$ for handling at the counter - one office in front of the place where you got your original airbill.
6. Get your freight-release-form from the place where you got your original airbill.
7. Let your bike get out of storage - just 50 metres down the hall. Build it together. They are kind to provide you with a crowbar and you can even leave all your rubbish here.
8. Go to customs clearance
here. 6th floor, first room on the right. (Closed between 1pm and 2pm!)
9. Go with the folder they gave you down to the ground floor and turn to the left when you get out of the building. The big entrance to the left of you after 20 meters is where you get a signature at one of the counters. Just approach them directly. Doesn't even take them a minute.
10. Go
here with the bike and let your chassis and engine number get checked. They should write you something on the back of the slip and into the book.
11. Return back at the customs office in the 6th floor, giving back the folder and leaving your slip of the carnet there. Make sure to let them give you a copy of it as it serves as your exit permit - weirdly.
12. Go to exit-gate 4 or 5, depending on which is open. Hand them the slip and leave.
13. Fuel up just 2 km away at
Petronas on the highway to the North. Warning, no air available. The first air I found available was
here. (My air pump gave up - was lucky to move at all)
And you're done. I started the process at 9.30 am and was completely done at 3.30pm. Get rid of about 30 minutes to an hour of unnecessary walks and have an easier build-up than mine saving yourself about the same amount of time again and you can easily be in KL in the early afternoon. The only costs I had to pay were the 50$ handling charge. No questions asked about insurance.
Hope it helps!