In the course of the first season's shooting, Ron Ely (Tarzan), who insisted on performing his own stunts, sustained seventeen different injuries. These included: singeing his arms and legs running through a burning village, being bitten on the forehead by a "tame" lion (in a later fight with the same lion, he was bitten on the lower left thigh), falling down a hill and ripping the skin off the tops of his feet, falling twenty-five feet (7.6 meters) off of a vine and separating his shoulder, falling off of another vine and breaking his other shoulder, fracturing three ribs, and spraining both wrists.
Mike Henry, who had just filmed several big-screen adventures as Tarzan, was to have also played the lead on this show, but backed out. Ron Ely, who took his place, was originally to have performed as a Tarzan impostor in a proposed episode of this show.
Unlike numerous cinematic film adaptations, Tarzan's mate Jane is entirely absent in this production. The decision of omitting this female character was Sy Weintraub 's idea. He replaced the adoptive son, Boy with a young orphaned boy named Jai.