[pyrodex]

I also reset it to playcount 0 and can confirm it comes back in the unwatched filter but the resume marker stays and the timecode in the DB to resume from.

Playcount (which determines if something is considered watched) is unrelated to resume point.

You can clear the resume point using "Reset resume position" on the context menu, which has no effect on the current playcount. A partially watched episode can be marked as unwatched - resetting the playcount to zero - but this will not remove the current resume point.

My MAC machine is using the same DB but just checked on it and a Windows box all running the latest nightlies and they exhibit the same problem.

That's to be expected, as there's nothing specific to these builds that is likely to be contributing to your problem (I think I said this a while ago!) however I'm not entirely clear on what the problem is, unless you are saying the playcount is being bumped without reaching 90%? Maybe it's an addon that is doing it?

I also read the Wiki article and don't have any special watched settings. I was aware of the default values and have experienced Kodi marking an episode watched in the past when I was like 93% and had to stop for some reason, this is why I put a soft toggle unwatched/watched button on my Harmony remote for this case.

I believe the default is 90%, so that behaviour would sound like it is working as intended. At what percentage do you experience the playcount being bumped?

So on a machine with #1003 (Rolled back due to labels for this test) I created a new kodi directory, added my sources, and my advanced settings (MySQL configuration) and didn't see the issue. I am seeing playcount bumped prior to 90% and with a FRESH kodi directory this doesn't occur. 

Here are the addons I had added but not sure why any of these would be doing it...

Code:

game.controller.default
metadata.album.universal
metadata.artists.universal
metadata.common.fanart.tv
metadata.common.imdb.com
metadata.common.musicbrainz.org
metadata.common.theaudiodb.com
metadata.common.themoviedb.org
metadata.themoviedb.org
metadata.tvdb.com
packages
plugin.video.discovery-channels
plugin.video.diy
plugin.video.youtube
pvr.mythtv
script.module.beautifulsoup4
script.module.html5lib
script.module.mechanize
script.module.requests
script.module.simplejson
script.module.six
script.module.t1mlib
weather.yahoo