Yessss, found a store that sold me a used rear tire with about 85% of it's tread left for an ok price despite the holiday. Got the Metzler Endurance which I had my doubts that it would fit. But installed it on the klr and she fits perfectly. Changed the oil and cleaned the air filter today as well. She's like a new bike! Picked up some patches and some new glue as well for free.
As for some comments in the guestbook - We took the tire off the rim completely and looked thoroughly through both. Didn't find a single thing. The bead does have a crack in it. That tire is now out of my life. We are starting the trip north tomorrow finally.
Below are pictures of the warped bead. Pain in the ....