The saga continues...
After removing the biamping setup of my fronts and resetting the receiver ahead of an attempted firmware update (that failed, not able to connect to Denon servers even following all recommended steps), I had two more startups with 4 of my 5 speakers not playing.
Then, magically, all of a sudden this problem stopped occurring and hasn't returned in more than 10 subsequent avr startups.
BUT, before anyone jumps to biamping or the reset as the culprit / fix: I realize now that this very problem actually first occurred the first time I hooked the unit up after purchasing and resetting it... I went through Audyssey and countless times, one or more speakers, especially the side surrounds wouldn't emit a tone during the measurement cycle. At that time, the receiver had been reset and the fronts weren't biamped.
So I'm going to keep monitoring this, of course, but if the problem doesn't return will be happy to keep this unit for a while.
To me, the 3808-CI sounds very good and apparently has an awesome Amp section / PSU just based on some comparative power measurements:
www.avsforum.com
Re the comments about my 5CH Stereo setup. I cross over to my sub at 80hz, listen at very moderate volumes and the Klipschs are easy to drive. This should be pretty easy on the amps. I've played 5CH stereo on other Denon AVRs and different speakers for years w/o a problem, just not very loud.
There are very specific reasons I play music this way. My room is very long with a high vaulted ceiling and the way I have the speakers setup and calibrated relative to the MLP creates a very enveloping sound stage where the sides almost sound like front wides. I don't obsess over instrument placement in the stereo field and absolutely prefer this to 2 or 2.1 listening in this specific room. For the future, I'm considering a separate setup in a different room, focused on music listening with a dac, stereo amp and different speakers but until then, this is what I have room for.
Lastly, tapping the cones would only bring that specific speaker back.
Thanks for everyone chiming in here, great forum / group.