fix(openrouter): keep DeepSeek V4 reasoning effort valid (#77423)

Summary:
- The PR removes `max` from OpenRouter DeepSeek V4 thinking profiles, maps stale OpenRouter `max` overrides to `xhigh`, preserves direct DeepSeek behavior, and updates docs, tests, and changelog.
- Reproducibility: yes. Source inspection on current main shows OpenRouter DeepSeek V4 advertises `max` and se ... ffort: "max"`, matching the linked 400 logs; I did not need a live OpenRouter request for this assist pass.

Automerge notes:
- Ran the ClawSweeper repair loop before final review.
- Addressed earlier ClawSweeper review findings before merge.
- Included post-review commit in the final squash: docs(changelog): credit OpenRouter duplicate fix
- Included post-review commit in the final squash: fix(openrouter): keep DeepSeek V4 reasoning effort valid

Validation:
- ClawSweeper review passed for head becdea4223.
- Required merge gates passed before the squash merge.

Prepared head SHA: becdea4223
Review: https://github.com/openclaw/openclaw/pull/77423#issuecomment-4372880583

Co-authored-by: sallyom <somalley@redhat.com>
Co-authored-by: clawsweeper <274271284+clawsweeper[bot]@users.noreply.github.com>

extensions/openrouter/index.test.ts

@@ -73,7 +73,7 @@ describe("openrouter provider hooks", () => {
 
   it("advertises xhigh thinking for OpenRouter-routed DeepSeek V4 models", async () => {
     const provider = await registerSingleProviderPlugin(openrouterPlugin);
-    const expectedV4Levels = ["off", "minimal", "low", "medium", "high", "xhigh", "max"];
+    const expectedV4Levels = ["off", "minimal", "low", "medium", "high", "xhigh"];
 
     expect(
       provider
@@ -309,7 +309,7 @@ describe("openrouter provider hooks", () => {
 
     expect(capturedPayload).toMatchObject({
       thinking: { type: "enabled" },
-      reasoning_effort: "max",
+      reasoning_effort: "xhigh",
       messages: [
         { role: "user", content: "read file" },
         {
@@ -324,6 +324,50 @@ describe("openrouter provider hooks", () => {
     expect(baseStreamFn).toHaveBeenCalledOnce();
   });
 
+  it("keeps OpenRouter DeepSeek V4 reasoning_effort within OpenRouter values", async () => {
+    const provider = await registerSingleProviderPlugin(openrouterPlugin);
+    const payloads: Array<Record<string, unknown>> = [];
+    const baseStreamFn = vi.fn(
+      (
+        ...args: Parameters<import("@mariozechner/pi-agent-core").StreamFn>
+      ): ReturnType<import("@mariozechner/pi-agent-core").StreamFn> => {
+        const payload = { messages: [] };
+        void args[2]?.onPayload?.(payload, args[0]);
+        payloads.push(payload);
+        return { async *[Symbol.asyncIterator]() {} } as never;
+      },
+    );
+
+    for (const thinkingLevel of ["minimal", "low", "medium", "high", "xhigh", "max"] as const) {
+      const wrapped = provider.wrapStreamFn?.({
+        provider: "openrouter",
+        modelId: "openrouter/deepseek/deepseek-v4-pro",
+        streamFn: baseStreamFn,
+        thinkingLevel,
+      } as never);
+      void wrapped?.(
+        {
+          provider: "openrouter",
+          api: "openai-completions",
+          id: "openrouter/deepseek/deepseek-v4-pro",
+          baseUrl: "https://openrouter.ai/api/v1",
+          compat: {},
+        } as never,
+        { messages: [] } as never,
+        {},
+      );
+    }
+
+    expect(payloads.map((payload) => payload.reasoning_effort)).toEqual([
+      "minimal",
+      "low",
+      "medium",
+      "high",
+      "xhigh",
+      "xhigh",
+    ]);
+  });
+
   it("recognizes full OpenRouter DeepSeek V4 refs but skips custom proxy routes", async () => {
     const provider = await registerSingleProviderPlugin(openrouterPlugin);
     const payloads: Array<Record<string, unknown>> = [];

extensions/openrouter/stream.ts

@@ -3,6 +3,8 @@ import type { ProviderWrapStreamFnContext } from "openclaw/plugin-sdk/plugin-ent
 import { OPENROUTER_THINKING_STREAM_HOOKS } from "openclaw/plugin-sdk/provider-stream-family";
 import {
   createDeepSeekV4OpenAICompatibleThinkingWrapper,
+  type DeepSeekV4ReasoningEffort,
+  type DeepSeekV4ThinkingLevel,
   createPayloadPatchStreamWrapper,
   stripTrailingAssistantPrefillMessages,
 } from "openclaw/plugin-sdk/provider-stream-shared";
@@ -55,6 +57,27 @@ function shouldPatchDeepSeekV4OpenRouterPayload(model: Parameters<StreamFn>[0]):
   );
 }
 
+function resolveOpenRouterDeepSeekV4ReasoningEffort(
+  thinkingLevel: DeepSeekV4ThinkingLevel,
+): DeepSeekV4ReasoningEffort {
+  switch (thinkingLevel) {
+    case "minimal":
+    case "low":
+    case "medium":
+    case "high":
+    case "xhigh":
+      return thinkingLevel;
+    case "max":
+      return "xhigh";
+    case "adaptive":
+      return "medium";
+    case "off":
+    case undefined:
+      return "high";
+  }
+  return "high";
+}
+
 function isEnabledReasoningValue(value: unknown): boolean {
   if (value === undefined || value === null || value === false) {
     return false;
@@ -125,6 +148,7 @@ function createOpenRouterDeepSeekV4ThinkingWrapper(
     baseStreamFn,
     thinkingLevel,
     shouldPatchModel: shouldPatchDeepSeekV4OpenRouterPayload,
+    resolveReasoningEffort: resolveOpenRouterDeepSeekV4ReasoningEffort,
   });
 }
 
@@ -156,12 +180,3 @@ export function wrapOpenRouterProviderStream(
     createOpenRouterDeepSeekV4ThinkingWrapper(wrappedStreamFn, ctx.thinkingLevel),
   );
 }
-
-export const __testing = {
-  isOpenRouterDeepSeekV4ModelId,
-  isOpenRouterAnthropicModelId,
-  isOpenRouterReasoningPayloadEnabled,
-  isVerifiedOpenRouterRoute,
-  shouldPatchDeepSeekV4OpenRouterPayload,
-  shouldPatchAnthropicOpenRouterPayload,
-};

extensions/openrouter/thinking-policy.ts

@@ -8,7 +8,6 @@ const OPENROUTER_DEEPSEEK_V4_THINKING_LEVEL_IDS = [
   "medium",
   "high",
   "xhigh",
-  "max",
 ] as const;
 
 function buildOpenRouterDeepSeekV4ThinkingLevel(