I have a 07 outlander 400 with 2,200 miles on it. I dont have any noise like the one you are talking about. I love the power and ride of it. The only two things mine does that I don't like are it seems to start hard no matter cold or warm and when I use the brakes they make a grinding noise. Its made that noise from the time bought it at 350 miles till now. More so when the brakes get wet or even if its real dusty. Hope you solve your problem.

 

About $76. (shop manual)from the dealer........

 

Any update on this fourlix? I have a 2004 outlander 400 with a noise and I tried pulling the start out and pull started it and still have the noise. I had recently changed the timing chain as it was stretched and adjusted the valve clearance and I still have the same knocking noise as before doing all this. Am going to try pulling the primary off to see if I still have the noise to try and rule out the clutch and tranny.

 

Interesting how when this thread started my Outlanders weren't even built yet, whereas now they are 10 and 11 years old.
#1 2004 Outlander XT bought from Washington states public surplus (Not a smart idea, although the service was consistent,) but you know how they rode it.. Body rough with noises , and a rear brake where the pedal wouldn't let loose, and a few other issues .
Got to know the fuel system quite well to get it up and running before I could find the other issues

#2 2005 Outlander with 300 miles that has been garaged most of its days. REALLY got to know the fuel system on this one since it had a fuel pump that didn't belong on it and was installed by a novice mechanic (if that experienced). Changed that for original equipment and cleaned the Chit out of the carb. (it was nasty) and she runs like a champ now. Sure was glad I spent that $76 on that manual last year and had an example (04) in front of me.