Thanks dude1 and rcaffin for your help.
I changed the step frequency in the smooth stepper settings as per the recommended:
X axis: 128 kHz
Z axis: 32 Khz
A axis 64 Khz

I then went into the motor tuning settings and set to the max velocity and then set my acceleration, they seem smoother and a bit faster, so I'll happy with that.
I also tested my original program again using v040 (I know I shouldn't bother, and just try to figure out the feed hold issue for v062, I'm just curious).
BTW, with v062, if I'm running a basic program I press feed hold, it displays PAUSE then pauses a second or two later, the small delay is fine, but with a more involved program (coincidence maybe???) I press the space bar and nothing, it doesn't even display pause, no matter how many times I press it, I would love to figure out this pausing issue, it would solve all of my problems......I'm pretty sure my wife would disagree though!

Oh I also forgot to ask, if I change the kernal speed to 25 kHz, will I need to re-tune the motors?

This below program works...
;Annular plunge grinding example with finishing cycle
#1=48
#2=47.5
#3=6
#4=2
#5=24
#6=0
#7=4
#8=-1874919423
#9=0
#10=0.1
#11=0.025
#12=12000
#13=3500
#14=0.475
#15=5
#21=10
#23=0
#24=0
#25=1
#28=3
#16=1.5
#17=0.5
#18=[[#6/[#5+#3]]*#3]
#20=3
#22=-1.1520495086364e-006
#26=[360/#7]
#27=[#22*#4]
#29=5
G90 G21 G57
G18
M208
G90 G0 Z0.
G4 P2
G0 X[#2+#11+#17+#21]
A0
M98 P1 L#20
G90 G0 Z0.
A0.
G0 X[#2+#11+#21+0.3]
M98 P4 L#29
G90 G0 X[#2+#11+#17+#21]
M208
Z0. A0
G0 X[#1+#21]
G4 P1
M18
M16
M30
O1
G91 G0 X[#21-[#21*2]]
M98 P2 L#15
G91 G1 A720 F#12
G1 X[#17+#21] F300 ;IF I USE G0, IT WOULD JOLT X AXIS OUT AND TRIP THE SERVO
G0 X[[#18-[#18*2]]*#4] Z[[#3*#4]-[[#3*#4]*2]] A[[#22-[#22*2]]*#4]
M99
O2
G91 G1 X[#10-[#10*2]] A360 F#12
M98 P3 L1
M99
O3
M99
O4
G91 G0 X[#21-[#21*2]]
M98 P5 L1
G0 X#21;THIS LINE SHOULD ALSO TRIP OUT THE SERVO, BUT DOESN'T?
G0 X[#18-[#18*2]] Z[[#3*#25]-[[#3*#25]*2]] A[#22-[#22*2]]
M99
O5
G91 G1 X[[#11-[#11*2]]-.3] A360 F#13
M98 P6 L#28
G91 G1 X[#9+0.3] A#26 F#13
G91 G0 X#11
M99
O6
G91 G1 A360. F#13
M99

If you change the kernal speed you are advised to revisit the motor tuning.
Cheers
Roger

+1 to rodger if it works better at 25 it's a over flow, one suggestion was to use a delay before the contuse A move so everything is at that point in time

And Warp9 recommend 25 kHz with the ESS anyhow. No need for anything faster.

Cheers
Roger (without the 'd')

auto correct sux's

Snerk 

If youa re still having the issue with the X movement error after an A axis move.  I have experienced an issue a few years ago while trying to do 3D rotary machining.  My A axis was tuned alot faster then my other 3.  This caused the X axis to stall and or freak out as soon as the A axis stopped its rotation and the X axis was asked to move.

Oh really?
Details, please, including Mach version number.

Sigh - not another bug??? But if it is, then it might be possible to find a 'fix'.

Cheers
Roger

This was years ago.  I do not recall the version number.  I had a sherline rotary which had 800 steps per.  I had the motor tuning ALOT faster then the others.  There was no need to have it tuned that fast as it was only stepping a very small amount.  my best uneducated guess was the amount of resources it took to process the velocity of the A, When X moved it freaked.  Sounds alot like the OP`s description.

you need to have the speeds between A and the other Axis set so they move at the same speed, this means the A Axis has to go faster than X, Y or Z, but when in practice if you set the A axis at the same speed the A will be slower you just need to bring up the speed of the A axis so it looks correct on my machine it's 1250 mm/min for X, Y and Z and A is 2200 mm/min and it runs very well it was a lot of slow cutting to get it correct it's just play to it looks good.

but if you get the A axis going to fast it will make thing go wrong fast there is a fine line between bonkers and all good