Third seed Juan Carlos Ferrero came through the wars before seeing off Italy's Filippo Volandri.
The Spaniard, French Open winner and US Open finalist last year, was treated for a back problem in the first set.
He came through that and then injured his left arm while reaching for a low shot in the third set.
Volandri had the power to trouble Ferrero but was undone in the end by his 53 unforced errors and the Spaniard came through 6-4 7-6 (7/3) 7-5.
"Everything is OK," Ferrero commented afterwards about his injury concerns.
"I went to the doctor and he told me to take some
anti-inflammatories but he thinks it's going to be OK," he added.
Another man suffering during his match was Australian wild card Todd Reid.
Reid had to overcome cramp and a bout of vomiting, before he overcame Sargis Sargsian in five sets.
"I was cramping in that fourth set and then I just chucked
it all up and the cramping stopped," Reid said.
"The cramp was making my leg twitch a bit and when I
chucked up it just relieved me so much - I was so pleased to
get it up."
Lleyton Hewitt had a scare before sealing his place in round three.
Hewitt lost the first set 6-1 to Slovakian Karol Kucera, before coming back to win 1-6 6-1 6-4 6-1.
Hewitt's third-round opponent will be the rising star Rafael Nadal.
Seventeen-year-old Nadal was a 6-4 3-6 7-5 6-1 winner over France's Thierry Ascione.
Second seed Roger Federer was very impressive again and has yet to drop a set after a 6-2 6-3 6-4 win over Jeff Morrison.
Marathon man Albert Costa was again taken the distance, this time by local hero Wayne Arthurs.
Costa twice came from a set down before winning 6-7 (5/7) 7-5 4-6
Fourteenth seed Jiri Novak took the bragging rights against fellow Czech player Jan Vacek, with a 6-2 7-6 (7/3) 6-4 win.
Fortune had smiled on Vacek earlier as he had only earned his place in the main draw as a lucky loser from qualifying, but his luck ran out against Novak.