HA!!!! I KNEW IT!!!!
I just KNEW this show existed and I wasn't imagining it!!! I can't believe I finally figured out what this was that I used to watch when I was 8. All I had to go on from memory was it being a live-action saturday morning show about a hamburger-shaped robot, some blonde, curly haired kid, and a couple bounty hunters or something who dressed in black that were chasing after them.
Funny how I had absolutely no recollection of Benji, no wonder I couldn't figure out what the heck this was until now.
Man, that's been buggin' me for years. Awesome, now I can sleep at night.