Totals:
Heart Throb: 19
Megan: 19
Wind Whistler: 18
Posey: 17
Buttons: 16 (+ 1 animation error)
North Star: 16
Gusty: 15 (+ 1 animation error)
Lickety-Split: 14 (+ 1 animation error)
Ribbon: 14 (+ 1 animation error)
Paradise: 14 (+ 1 animation error)
Spike: 14 (mentioned in 1 episode)
Fizzy: 14
Whizzer: 14
Surprise: 13 (+ 1 animation error)
Galaxy: 13 (+ 1 animation error)
Shady: 12 (+ 2 animation errors)
Sweet Stuff: 12 (+ 1 animation error)
Lofty: 12 (+ 1 animation error)
Cupcake: 12 (+ 1 animation error)
Baby Lofty: 12
Magic Star: 11 (+ 3 animation errors)
Cherries Jubilee: 11 (mentioned in one ep; 1 animation error)
Baby Ribbon: 11 (+ 1 animation error)
Truly: 10 (mentioned in one ep; 2 animation errors, and one where idk if it's her or Sundance)
Sundance: 10 (+ 2 animation error appearances, and 1 where idk if it's her or Truly)
Baby Lickety Split: 10 (+ 1 animation error)
Gingerbread: 10
Baby Heart Throb: 10
Masquerade: 10
Baby Cuddles: 9 (+ 1 animation error)
Baby Half Note: 9
Baby Tiddley-Winks: 8 (+ 1 possible animation error)
Danny: 8 (mentioned in 1 episode)
Molly: 8
Baby Shady: 8
Sun Shower: 7
Baby Sundance: 6 (+ 1 animation error)
Baby Gusty: 6
Sea Shimmer: 4 (+ 1 animation error)
Water Lily: 4
Morning Glory: 4
Rosedust: 4
Ripple: 4
Locket: 4
Surf Rider: 3 (mentioned in one ep)
Peach Blossom: 3 (possibly 4)
Forget-Me-Not: 3 (possibly 4)
Honeysuckle: 3
Lily: 3
Beachcomber: 3
SS Twilight: 2
Baby North Star: 2
FT Baby Lickety Split: 2
Baby Quackers: 2
Sniffles: 2
Snookums: 2
Milkweed: 2
Tumbleweed: 2
Baby Tic-Tac-Toe: 2
Baby Bouncy: 2
Baby Sleepy Pie: 1 (possibly 2)
Firefly: 1
Medley: 1
Twilight: 1
Bow-Tie: 1
Moondancer: 1
"Miss Mystery": 1
Ember: 1
Bubbles: 1
Glory: 1
Applejack: 1
Cotton Candy: 1
Seawinkle: 1
Wavedancer: 1
Sealight: 1
Skydancer: 1
Whitecap: 1
Sea Mist: 1
Sand Dollar: 1
Baby Moondancer: 1
Backstroke: 1
Sparkler: 1
Powder: 1
Starflower: 1
Baby Cotton Candy: 1
Baby Surprise: 1
Baby Glory: 1
Baby Fifi: 1
Baby Buttons: 1 (animation error, probably)
Princess Tiffany: 1
Princess Starburst: 1
Princess Sparkle: 1
Princess Royal Blue: 1
Princess Serena: 1
Princess Primrose: 1
Mimic: 1
Scoops: 1
Quarterback: 1
Steamer: 1
4-Speed: 1
Salty: 1
Tex: 1
Slugger: 1

"The Return of Tambelon" is the one with the most cast members; the only recurring (i.e. not one-off) characters that don't appear are Truly, Ripple and Beachcomber; Surf Rider doesn't appear "in person", but she is mentioned.
The other two episodes with the most ponies appearing are "The Ghost of Paradise Estate" (missing Water Lily, Lofty, the flutter ponies and Sea Shimmer) and "The Magic Coins" (missing Baby Gusty, the flutter ponies, Baby Heart Throb and Baby Tiddley-Winks).
(This is, of course, not counting the First Tooth babies, Locket, So Soft Twilight; as they only appear in a couple of episodes, right at the end of the show, it seemed odd to note their absence from these early eps.)

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