Restored your post.
This is a most peculiar set of symptoms. The pop is almost certainly being generated within the plugin.
Does it still occur when the plugin's volume control is turned down, or when the plugin is bypassed?
Does it occur if you mute the master bus, as opposed to turning it way down? Some plugins have been known to generate bursts of ridiculously high levels, like +99 dB, that might remain audible even with the master fader down.
Are you sure the plugin is routed through your master bus, and you haven't inadvertently sent it directly to the hardware outs? With SONAR's master bus muted, SONAR is not sending audio data to the driver. If the synth is properly routed and SONAR's master bus muted it's guaranteed there will be no sound
from SONAR. It would have to be another process injecting audio into the output buffers.