Yes, Michael hit Kevin Sorbo with a sword during filming of "Warrior Princess".
It occured during the fight between Iolaus and Hercules at Xena's camp. It was an accident and Kevin required 9 stitches in the back of his head.
How Michael Hurst broke his arm in season 2
During filming of the barn fight in the Xena episode, "Prometheus", A stunt man fell on Michael Hurst's right forearm and broke it. They hid the arm during the remainder of the filming for that episode. If you pay attention, you can see him hiding it behind him or just below the camera frame. the poor guy also appears to be "zoned out" in several scenes in which Iolaus has no lines but is required to stand in the background. His broken arm was written into the script on the set during filming of "Cast a Giant Shadow" inwhich the episode begins with Iolaus being grabbed from a sound sleep by a warlord looking for Hercules. Said warlord breaks Iolaus' right arm. Iolaus' arm remained broken and in a cast for the next couple of episodes filmed, "Highway to Hades" and "Once a Hero". Iolaus has a leather sling that holds his arm to his body in "Once A Hero". "Sword of Veracity" and "Enforcer" are aired in between those episodes but the arm is not in a cast. The gauntlet Michael was wearing on that arm had been modified to come up over that hand like a brace or perhaps to hide a brace.There's a moment in Sword of Veracity where the actor playing Amphion goes to shake Iolaus' hand, and you can tell he's being extremely careful. The fight scenes in these episodes appear to be favoring Iolaus' arm as well.
One author's perspecitve -Martha Wells Wilson
The way I looked at it, Iolaus got his arm broken in "Cast a Giant Shadow"
and it had nearly healed up again by the time they encountered the Enforcer. She broke it again and that's why we see it in the full cast with the sling in "Once a Hero".
Kevin Sorbo's aneurysm in season 4
During filming of the second half of Season 4, while in the US Kevin Sorbo was rushed to the hospital with an aneurysm (blood clot) in his shoulder. Emergency surgery was performed and Kevin would be fine but he could not work for several weeks. So, scripts has to be written at the last minute, writing Hercules out of the series for several episodes and then several other episodes had to be rewritten so that Hercules had a smaller part. This event also delayed the beginning of the Dahok arc. According to an interview in Xena magazine, originally, Iolaus and Gabrielle were to die together and Hercules and Xena were supposed to have to work together against Dahok to get them back.
Where did the scar on Iolaus' forehead come from?
Iolaus comes by the scar second hand. It actually belongs to Michael Hurst. when he was little he fell and hit his head on a table.
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