I guess the first question would be, why on earth are you opposed to using SSL/TLS, which after all is more secure?
But assuming you have a good reason, the next question is, is your Outlook internal to the LAN where the mail server is, or is it external? If internal, have you got your lan IP range in the MTA Trusted Networks (in the admin GUI, go to Servers, click on the domain, click on the MTA tab, and see the options in MTA Trusted Networks)? While you're on that tab, and also on the MTA tab in "Global Settings," make sure that "TLS Authentication Only" is unchecked.
Not for sending, but for receiving of email, you'll also have to check "Enable clear text login" for both IMAP and POP. Again, I don't recommend this, but if you don't want to use SSL you'll have to. . .
If it's on the outside, you really ought to consider using SSL, but you need to verify in either case that your firewall is passing port 25 traffic correctly.
Once you've made these changes, stop & restart Zimbra services and see if you're still having the problem.
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Cheers,
Dan
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