I had the same problem when I was wearing the ICON Alliance helmets. I talked to the ICON rep at a MC expo, and he said they were aware of the problem and sent me some different connectors for the helmet. Write to ICON
http://www.rideicon.com/ and maybe they'll send you some replacements. BTW: I liked the alliance helmet cause it fit my head so well. I have a Soumy Spec 1R now, and the fit isn't as good. The noise level is better, and the weight is lighter, but the fit isn't there. Usually 4 to 5 years is when you should replace your helmet. Soumy says their helmets are good for 7 years after manufacture and 5 years after initial wear.
BTW: I got around the face shield flip up, by tucking my chin into my chest before looking back. It sounds awkward, but it's easy.