There were five American settings used, not including the Japanese footage... they were Sam's Basement, The High School Hallway, The High School Cafeteria, Malcom's Closet, and the Cockpit (1 location used for 3 different vehicles).
'Kevin Castro''s character, Tanker, was the only person besides Sam ('Matthew Lawrence') to transform into Servo.
Troy W. Slaten's character, Amp, is the only one to change his quote every time they go into battle. Sam's quote: "Let's samuraize!" Tanker's quote: "Let's kick some giga-butt!" Syd's quote: "Pump up the power!" Lucky's quote: "Surf's up!"
Glen Beaudin and Tim Curry worked closely together on the series; yet not once did they ever meet face-to-face throughout its entire run.
On one occasion, Glen Beaudin was nearly fired from the show for ad-libbing a barrage of dirty language while taping one of his scenes with "Kilokahn". The producers did not discover he had done this until reviewing the sequence much later.
The series is rife with Beatles references ranging from movie quotes to song lyrics -- a pet joke of the series story editors, Magon and Zaslove.
Episode 105 is the first show in which Sam uses his Wrist Communicator to record and playback the magic , as a substitute for his guitar.