This is an email I sent to dynojet recently. I would also be very interested in others opinions. I'm a novice when it comes to carbs, I can follow instructions and do the work, but I'm no master when it comes to judging results... please comment.

The 04 and 05 xls are a bit different than the earlier xls....Seems that the dealer sold you a kit for the earlier xl......needles and emultion tubes are the same, simply go by the 04 and 05 instructions. If you don't have a 175 but do have a 180, use the 180 main jet.
The 04 and 05 s have better cams and heads flow better than the earlier xls thats why the difference in the fueling.

 

I have the Dynojet kit #8135 for 04-05 1200's. Using their instructions for air and exhaust mods, I'm running the 175 4th clip and stock pilot 3.5 turns on the airscrew. It works very well!

 

Thanks for the replies guys. Here is the response from dynojet in case anyone is interested:

if at steady cruise the bike is smooth and doesn't hesitate or surge change nothing. but if it does surge or hesitate move to groove 4 on the needle. if when you accelerate to pass a car (snapping open the throttle) and it hesitate go up to a 175/180 mainjet. but if no noticeable problem then leave it where its at.

My bike runs ok (have had the 170 main in there for about 2000 miles) but I do think I'm going to try the 180 jet and 4th notch to see if there is a performace difference.