Sanjay Khan was born as Shah Abbas Khan on 3 January 1940 in Bangalore, India. He was educated at St. Germain High School in Bangalore. Before establishing himself as an actor, he worked with Hollywood filmmaker John Guillermin during the production of Tarzan Goes to India (1962).
He entered Hindi cinema in 1964, initially appearing briefly in Haqeeqat. His official acting career began around the same period, and he quickly became known for his handsome appearance, commanding personality, and leading-man roles. His filmography includes more than 30 movies, with his major acting period extending from 1964 to 1986.
Sanjay Khan later expanded his career into film direction and production. He directed and produced films including Abdullah (1980) and was involved in the production of Chandi Sona. He also worked extensively in television, becoming particularly associated with historical and mythological productions.
One of the most dramatic incidents of his career occurred in 1989 during the filming of The Sword of Tipu Sultan. A major fire at Premier Studios in Mysore left him with severe burns and required prolonged hospitalisation and extensive medical treatment. Despite the life-threatening injuries, he eventually recovered and continued working in television and production.
Sanjay Khan subsequently produced and directed television projects including The Sword of Tipu Sultan, The Great Maratha, Jai Hanuman, and Sanjay Khan's Mahabharat. His official biography describes his continuing involvement in creative and charitable projects.