When the second season crew took over, they brought in Don Messick to play Dr. Benton Quest. But Messick's poor health condition caused difficulty for him while playing Dr. Quest in the first few episodes of the second season, so they had to replace him with John de Lancie, who redubbed the episodes, in which Messick had played. But one line of dialogue by Messick wasn't re-dubbed, his "and not a moment too soon" can be heard in season two, episode two, "Rock of Rages".
Hadji was portrayed as a computer expert because the writers knew that at the time of the show's production, India was becoming more involved with such technology. It was meant to reflect the potential future of that country.
The development of the show began in late 1992. By December 1995, not one single episode had gone beyond pre-production stage, and eleven million dollars had been spent by the first season crew, led by Peter Lawrence and Takashi Masunaga, so they were fired. Originally, there were supposed to be fifty-two episodes for the show, but thirteen were cut to recover some of the losses. Glenn Leopold worked for a short time as a writer in the first season and he didn't agree with the ideas of the crew for the show. So when the second season crew took over, Leopold came back on as the Story Editor and, along with Writer Lance Falk and Producers Davis Doi and Larry Houston, brought back the feel of the original 1960s series by reintroducing Dr. Zin, Jade, and other characters. Despite the fact that they "had" to use Questworld as a continuation, the crew tried to stay faithful to the original. Many scripts produced during the first season were found by them to be unairable, so Michael Ryan, the only first season writer aside from Leopold to return, had to come in and do "story polishing". When Houston was asked why the second season's episodes looked so different from the first's, he replied, "The original production staff, after three years of producing unairable and unfinished material, were let go and four new producers were brought in to meet the upcoming deadline: John Eng, Cosmo Anzilotti, Davis Doi, and myself, Larry Houston. John and Cosmo used the original models done by the previous staff, because of the lack of time. Davis and I, being old-time fans of the original 1960s series, decided to redo the models to be in between the original models and the models John and Cosmo was doing, to fit our aesthetics as to what the series should look like. Cartoon Network was supposed to launch our version separately from John and Cosmo's, but when Warner Brothers bought Hanna-Barbera and Cartoon Network, decisions were made, or not made, and that is why you have the differences."
The introduction theme song was influenced by the main theme of Speed (1994), composed by Mark Mancina.