I feel for you TQ,even though they replaced mine under warranty I find myself checking the tires out every time I go for a ride.I really think I am going to have to change makes before I am 100% confident again.
		
		
	 
Absolutely.  I am shocked by Dunlop's stance on this.  Seems to me this is a fairly wide-spread manufacturing problem that is very much a safety concern.  Not sure if that split is related to any of the "rapid deflation" issues, but I would have expected that they would want me to take my tire to ANY retailer of the D402s for evaluation/full warranty exchange as long as the tire tread depth is within usable specs.  Their warranty is full replacement for the first 50% tread depth life, and then 50% replacement for anything under 50% of new tread depth.
So.  Changing to AVON Venoms.  Yesterday afternoon ordered front and rear as follows:
Items Shipped 
Item Status Price Quantity Total Item Price 
AM42 Venom Rear Tire
Color - --, Size - 140/90HB-16
SKU# 50535 Shipped $150.99 1 $150.99 
AM41 Venom Front Tire
Color - --, Size - MT90HB-16
SKU# 50287 Shipped $131.99 1 $131.99 
Free S&H (Motorcycle-Superstore)
Interestingly, when I called one of the HD Dealerships here to talk about this problem, the Service guy had not heard of the problem.  I had to explain the issue and what Dunlop's warranty was.  He indicated that if I brought the bike in (how? towing?) they could have me out of there with a new Dunlop MU85-16 bw for $285.  What a deal!  (NOT!!)
Will let you know how the Avons do on the dresser.
TQ