Check the starter solenoid isn't sticking , you may have to pull the solenoid and or the starter motor out. Check all the connections are clean and tight. The small wire to the starter solenoid itself, and the larger positive wire to the motor from the battery.
If the stator windings are good, the rotor magnets are good and the engine runs, there has to be an alternating current output from the stator and if the wiring is correct, the combined rectifier and regulator is working correctly and the battery healthy, it must charge.
I think you have missed something...
Do you have an alternating current output from the stator when it is disconnected?
Some older machines, Honda in particular, had a convoluted method of regulating the charging current using the headlamp switch and it took a lot of staring at the circuit diagram to check it through...
Thanks for the details, they do help. Is there a way you can disconnect different electrical circuits from the battery? Like Disconnect the lights, horn, or other components then start adding them back until you find the circuit or group of wires that causes the short. Because it seems you have a short somewhere, or something really putting a load on that 30 Amp fuse. So I'd break the circuits down to smaller pieces so that when you reconnect the lights, or starter, or whatever....that the fuse pops and you know the circuit causing the issue. You may have to open engine components like a magneto to isolate the circuits. But it shouldn't cost you anything except time.
Hi, Surat and the usual suspects are:
1. Fouled spark plugs.
2. Severely discharged or a damaged battery, should have 12.5 volts or better and be able to pass a load test if necessary.
3. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
4. Loose connection at ignition coil or plug between ignition sensor and CDI box.
5. Spark plug cables in bad condition, shorting / leaking, spark plug cable connections loose, check for spark leakage in the dark.
6. Faulty ignition coil, pick up coil, trigger coil or CDI box testing needs to be checked with an ohmmeter at 70 degrees Fahrenheit
7. Faulty safety switches clutch, kickstand, neutral, off/on etc.
8. Faulty ignition switch.
For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have a nice day. Pulsar No spark on the right plug Team BHP http://www.xbhp.com/talkies/help-me/25313-pulsar-180-not-starting.html How to test motorcycle pickup coils How to test motorcycle CDI box ignition coil http://www.bcmtouring.com/imp/Pulsar_DTSi_Workshop_Manual.pdf