Rex Smith is a skilled motorcycle rider and did most of his riding. A stunt double was used for dangerous stunts.
Honda sued the producers and Universal television, claiming that the series name was too similar to their Nighthawk motorcycle. They dropped the suit after the series was cancelled.
The motorcycle in the pilot was based on a 1983 Honda XL500 trail bike. The motorcycles used in the series were based on 1984 Honda XR500s. The motorcycles used for the stunt shots were based on Honda CR250s. Overall, 15 motorcycles were used in the show. The whereabouts of 14 are unknown, but the 15th was in the now-closed Cars of the Stars Motor Museum in Keswick, Cumbria, England, restored by stuntman Chris Bromham. The pilot motorcycle was designed by Andrew Probert and the series motorcycles were redesigned by Ron Cobb. During stunt filming, fiberglass bike parts constantly flew off the bike during stunt jumps. The film stunt second unit crew always had six bikes standing by to replace the hero bike's jump or maneuver. The other stand-by motorcycles remained in the UNI special effects department shop being repaired, or replaced with fiberglass parts for the second stunt unit's next day's filming. When first unit was on stage at Universal Studios, the second stunt crew was on location, filming with a stunt biker performing with the bike. Rex Smith rode the motorcycle only with the first unit principle photography filming crew. The producers didn't want Rex doing stunts, afraid any injury to their star would jeopardize the tight daily schedule. A motorcycle shop three miles North on Lankershim Boulevard, not far from the studio, always supplied new frames and wheels for the stunt bikes. Winfield Special Projects in Canoga Park made all body panels and fenders. Eric Thaler from Austria was in charge of the project at Winfield's.
George Clooney screen tested for the role of Jesse Mach. Clooney was Robert Wolterstorff's first choice, but ABC didn't want him. He ended up guest appearing in the second episode.
Don Johnson was considered for the role of Jesse Mach. He became unavailable when NBC picked up Miami Vice (1984).
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