For Catman, you have to run the ball over the switch in the left most inlane (by either having the ball go directly into the inlane or hitting the center ramp and the ball dropping onto the switch) to light up/flash a face on the right orbit. Which ever faces are flashing when you hit the right orbit, you collect those. Collect all 4 to collect Catman. To complete Catman, I think you have to level them up twice, not sure about this though.

You need to hit both "Lite Lock" targets to get the "Lock" arrow to light up. Once you hit both and the "Lock" arrow is lit, you can lock a ball in Gene's mouth.

The hard part to describe is this... Like I just said above, hit both "Lite Lock" targets to get the "Lock" arrow to light up. Even if you don't get the ball into Gene's mouth, you can hit the two targets again to stack the 2nd lock. Then again to stack the third. However, you cannot hit the left target 3 times and then the right target 3 times. You have to hit each one, then it resets to let you hit them again. I hope that makes sense.

As far as getting the ball into Gene's mouth to light the "DEMON" letters, each time you get the ball in there, a letter lights up. Light all 5 letters and the "Lock" arrow with light up, regardless if you hit one or even none of the targets.

Spelling "DEMON" also helps to increase the jackpots during Demon Multiball.

I don't believe so. Once you light the 4 faces in the right orbit, the "Lite Bumper Shot" above the left most inlane goes dark and will not light up again until you hit the right orbit and collect what ever is flashing.

Edit: Not sure if I am reading your post correctly, so I will say this as well... you can make all 4 faces flash at the same time by hitting the "Lite Bumper Shot" switch multiple times and hit the right orbit to collect all 4 at once. You cannot hit it more than 4 times and stack, say the Gene Simmons face, and collect multiple levels of that particular face at once.