What is your audio buffer size, and what is the value of BounceBuffSizeMsec= in AUD.INI?
If the AUD.INI setting is not equal to 0, try that. If it is zero, and your audio buffer setting is below 4ms (176 samples at 44.1kHz) try raising either the AUD.INI value or your real-time audio buffer to the equivalent of 4ms or more.
When BounceBuffSizeMsec=0, SONAR uses your real-time buffer size for bouncing. In earlier version of SONAR, this could cause problems for some VSTis when the buffer was very small. But in X1, it appears they have made changes that can cause problems when the AUD.INI setting is not 0.