XR1000 and autocom pro 7
Sorry but I don't understand the problem, maybe I have a funny shaped head and ears.
I fitted the headphones where autocom tell you to fit them and don't have a problem apart from the velcro isn't quite good enough so occassionaly they move. My wife uses double sided sticky tape in her Schubert helmet.
Mike and plug are fitted to the left hand side which is a bit tight and not very neat but everything is tucked away and held in place with insulating tape.
The only difference now is the top of my ears get bent when I put my helmet on so I have to straighten them out with my hand before I do up the strap.
Volume - I was concerned that the ear plugs I use are too quite for the Autocom as it has no volume on the pro 7. Plugs are SNR 37 and I think Autocom recommend a max of SNR 20ish? Volume is fine for music, pillion, 2 way radio, mobile phone and GPS. The later upto about 70 (Motorway plus) then I tend to miss the voice but hear the beep. This is enough to glance down,pick up the next voice message and not miss the exit.
Overall very glad I spent the money and bought the Autocom system.