Thanks,
yeah part is 13161... the shifter forks with the engagement arm that push/pull the shift drum.
I pulled the clutch case. clutch/basket off to check it again. Sure as hell i found the arms not doing the job. Turned the shift drum manually and again it's shifting fine. Put it all back together but this time I put 2 washers on the shift shaft 13161 between the left sprocket cover/shaft support and the shifter knuckle (part 13242) it did tighten up the play I described above to about 1mm. To it out and tried to duplicate the problem but is is shifting fine now and seems to be cured but who knows as I thought is was fixed before too..
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