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Hi, it could be that the switch inners are not functioning properly, open switch and make shore it is cleaned and working ok,and check wire connections are good, just food for thought, all the best.
I have a '95 katana with a 4 to 1 vance and hines ss2 exhaust system. I grinded down original drain plug( drain oil and remove pan first) welded small piece of aluminium plate inside of pan on opposite side drilled and tap and bought oem drain plug no problems, problem solved!
89 Katana uses two coils, one fires cylinders 1 and 4 together and the other fires 2 and 3 together. It's a waste spark system. So your firing order is either one coil or the other every revolution.
Unforturntly yes! When you have it apart may as well freashen up the hole motor. If it need seals replace, if it need bearings replace, Messure the cyclinders and pistons and rebore and replace pistons,rings,gaskets ext ext. Being a 89 it would have alot of mile on it and if you rebuild the engine you will have a fresh engine and will have trouble free miles for a long time.
Sounds like fun, have you tried blocking the vacuum hoses engine side, engines sucking straight air will usually idle very fast, 89 should have one from manifold to fuel tap, rest are for carby tuning 7 should normally be blocked off.
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