I think I had same problem with my ignition barrel as yours a few years back.
Mine wouldn't give me anything unless I toyed with the key a little. Same as you I replaced the barrel and all was good.......for a while.
Six months later symptoms reappeared. I hated turning the key every time. Never knowing what I was going to get. I doubted that the barrel could go bad so quickly and did the checks your going through now. My fuses were never effected during all of this.
Now I know you might doubt trying it, but after running out of things to check with my meter and sockets I took a good look at my ignition whilst it was mounted. I don't know about yours but mine had a small cable tie securing the wiring just as it exited the bottom of the barrel. This keeps the cables nice and neat. It also in my opinion as looked at it, stressed the cables at a right angle to get them into the ignition. I didn't like this and cut the tie off. I used flush cutters for this as anything too heavy and I might nip a little too deep and then I would be in a mess.
Once off, I got " big red " out, rested it across my steering damper and gently levered against the base of the ignition," compressing it " I suppose is the best description. Well whatever I did, it now works fine.
Worth a check anyway. Best of luck mate and keep us up to date

 

well now sorted!
the 9 pin multi connector wasn't making a proper connection.
i must have disturbed it when connecting the ignition switch!
this little defect had me almost using lots of bad language.
no i did use lots of bad language!!
but now bike is starting ON THE BUTTON.

 

Glad your sorted

 

cheers CaBaRet.
thanks for your and all for your input!

 

So glad my last post was useless.

 

Glad you solved your problem Boru.

 

wes 17,your post was not useless!!
we will see in six months!
Hawk yes so am i!!!!!
thanks to all.