The original musical did a trial run tour which proved to be successful, and led to a transfer to the West End (which included some minor changes such as the recasting of the roles of Luisa and Ramon).

The musical originally opened at the Congress Theatre in Eastbourne with a five night run between 4–8 March 2008, before moving to the West End in July.

The musical began previews at the Garrick Theatre in London on 2 July 2008, after the first few were cancelled due to technical problems.

The cast featured Matt Rawle as Zorro/Diego De La Vega, Emma Williams as Luisa, Adam Levy as Ramon, Lesli Margherita as Inez, Nick Cavaliere as Sergeant Garcia, and Jonathan Newth as Don Alejandro De La Vega.

Aria Entertainment began a revival of the show at the Hope Mills Theatre in Manchester in March 2020, but the run was cut short after just two performances due to the COVID-19 pandemic.

Later, in Spain, Diego has run away from school and joined a band of gypsies who perform in the backstreets of the city ("Baila Me").

In California, Diego finds that Ramon has stripped the people of their rights and has put himself in charge ever since Don Alejandro "died."

He offers himself to Ramon as a personal servant, a move that angers Luisa, who believes that she brought Diego back for nothing.

After another spectacular rescue, Zorro flees from Ramon's guards and find himself in Luisa's room, having walked in on her while she is in the bath.

Meanwhile, the gypsies cause a stir in the pueblo by drinking and dancing together ("Bamboleo/There's a Tale"), enticing Ramon's cowardly but warm-hearted second-in-command Sergeant Garcia.

Ramon, initially intrigued by the idea of free wine, eventually turns against the gypsies and their radical ways and tries to prevent their activities.

Zorro appears just in time to save Luisa and tricks Ramon into accidentally admitting that Don Alejandro is still alive.

The second act opens with the band of gypsies from the prologue reappearing on stage and performing a large song and dance routine.

("Entrada") When the storyline continues, Ramon reveals the full extent of his injury: he is permanently scarred with the mark of Zorro.

After she dies in his arms, a heartbroken Zorro surrenders and is dragged away by the guards as Ramon forces Luisa to agree to marry him.

In his prison cell, Diego laments his failure to protect the people and blames himself for the suffering of the ones he loves ("Hope (Reprise)").

She wishes that she could have known the true identity of Zorro ("The Man Behind the Mask") and laments that in order to protect her love, she must sacrifice it as well as her happiness.

Michael Billington of the Guardian wrote, "The show may not be high art but it's great fun and brings a refreshingly different, Hispanic sound to the jaded world of West End musicals."

He also noted, “The show is popular theatre that actually delivers the goods.”[4] Michael Coveney of What's On Stage wrote, “An onstage flamenco fiesta that sets feet tapping and blood racing round the stalls.”[5] Charles Spencer of The Daily Telegraph referred to Zorro as, “An insanely enjoyable musical.”[6] In its preview, the Evening Standard stated that whether the show becomes a hit or flop, "an eclectic combination of talents and influences will make Zorro the musical memorable.

Since closing in London, Zorro has appeared in other countries such as France, Japan, China, Korea, the Netherlands, Russia, Bulgaria, Israel, and Brazil.

[9] In 2014, original star Lesli Margherita said that plans were in place to open a production of Zorro in New York in 2015.

The shortened Italian version was edited in collaboration with Stuntmanshow Production and Zorro USA LLC.