On my Vulcan I have 1.25" bars that taper to 1" for the controls (Harley Bars). The 1" portion is about .5" short on the throttle side. Is it Ok to have the throttle tube overhang the bar by that amount. If not, I will get a machine shop to fab 1" diameter, 2"length slugs to tack to the ends. Just take enough off to fit 1" into the bar ends and let the other inch over hang the bar. built in bar weights and extensions. Is it worth it, or can I just let it be?

I have an s40 as well. I value the opinions of the folks here. There is a lot of culmulative saddle time here and I've been lurking a long time.

I shined my s40 pipe with blue job and it worked well enough considering the rainbow I had for a header pipe. Next up; muffler and forward controls.

Run the bars as is. If the throttle sleeve breaks it gives you a perfect reason to upgrade. But it most likely won't.

I crashed my 800 Classic back in 08 and it didn't even scuff the left grip. Bent the bars, broke a mirror, ripped off a signal, obliterated the windshield...

Could you lengthen the bar ends where the grips go? I wouldnt solve that size problem till it proved to me it WAS a problem, but if the throttle gives you trouble, breaks, whatever,, then taking the bike to a welder, or take the bars,, & have a short piece welded on. A cool wet rag will keep the chrome from heating up..