For his role as "Mario" in the live-action segments, Lou Albano shaved his trademark goatee. Instead of wearing a false handlebar mustache, he opted to grow a real one.
Lou Albano and Danny Wells (Mario and Luigi) frequently improvised their dialogue when the two are on screen together.
On Monday - Thursday a "Super Mario Bros." cartoon was shown, but on Friday, a "Legend of Zelda" cartoon was shown in place of a "Super Mario Bros." cartoon. Scenes from the week's "The Legend of Zelda" episode were shown as sneak previews on the preceding days (Mon-Thurs).
According to the interview on Shout! Factory's first DVD box set, Lou Albano had stated that he was not interested in portraying Mario and voicing him at first, but was talked into it by his wife.
The reason the character of 'Indiana Joe' in 'Raiders of the Lost Mushroom' has no face is because the animators would animate the faces of the main characters first. Characters like Mario, Luigi, Toad, King Koopa, and Princess Toadstool. They had the face assets for Indiana Joe, but due to either time constraints or forgetfulness, he is left faceless.