2006 Polaris Sportsman 500 HO

[elksnout]

Meant to say it's drops to 10.22 with key fully engaged.

[ballpark]

That's not good.  If battery is fully charged that shouldn't happen until maybe long prolonged cranking.

[elksnout]

Starter is getting warm to the touch again.. 

[ballpark]

I hate electrical troubleshooting over the internet.  Sounds like solenoid is getting power to starter and starter is toast/grounded.  That might explain the voltage drop.

[Sandberm]

Take the starter apart, I tell ya there is something wrong there. Its getting juice but is unable to spin.

https://parts.polarisind.com/Assemblies.asp

[elksnout]

IT'S  ALIVE !!!

All weekend I kept thinking about how that starter was getting hot in addition to others suggestions on here. Overnighted one and swapped it out today. No small task.

Thanks for all of the help guys.

Elksnout

[ballpark]

 
Great machines, I have a 2005 Polaris Sportsman 500 HO, have worked on just about everything.  Glad to hear got it figured out.