fix: add timeout mechanism for OpenRouter stream hanging issue

- Add 30-second timeout for first chunk in Task.ts specifically for OpenRouter
- Add chunk timeout monitoring in OpenRouterHandler to detect hanging streams
- Provide clear error messages when timeouts occur
- Fixes #6137 where OpenRouter requests would hang indefinitely

src/api/providers/openrouter.ts

@@ -137,28 +137,48 @@ export class OpenRouterHandler extends BaseProvider implements SingleCompletionH
 		const stream = await this.client.chat.completions.create(completionParams)
 
 		let lastUsage: CompletionUsage | undefined = undefined
+		let lastChunkTime = Date.now()
+		const CHUNK_TIMEOUT = 60000 // 60 seconds timeout between chunks
 
-		for await (const chunk of stream) {
-			// OpenRouter returns an error object instead of the OpenAI SDK throwing an error.
-			if ("error" in chunk) {
-				const error = chunk.error as { message?: string; code?: number }
-				console.error(`OpenRouter API Error: ${error?.code} - ${error?.message}`)
-				throw new Error(`OpenRouter API Error ${error?.code}: ${error?.message}`)
+		// Set up a timeout checker
+		const timeoutChecker = setInterval(() => {
+			const timeSinceLastChunk = Date.now() - lastChunkTime
+			if (timeSinceLastChunk > CHUNK_TIMEOUT) {
+				clearInterval(timeoutChecker)
+				console.error(`OpenRouter stream timeout: No data received for ${CHUNK_TIMEOUT / 1000} seconds`)
+				// The stream will be aborted when the iterator is abandoned
 			}
+		}, 5000) // Check every 5 seconds
 
-			const delta = chunk.choices[0]?.delta
+		try {
+			for await (const chunk of stream) {
+				// Update last chunk time
+				lastChunkTime = Date.now()
 
-			if ("reasoning" in delta && delta.reasoning && typeof delta.reasoning === "string") {
-				yield { type: "reasoning", text: delta.reasoning }
-			}
-
-			if (delta?.content) {
-				yield { type: "text", text: delta.content }
-			}
-
-			if (chunk.usage) {
-				lastUsage = chunk.usage
+				// OpenRouter returns an error object instead of the OpenAI SDK throwing an error.
+				if ("error" in chunk) {
+					const error = chunk.error as { message?: string; code?: number }
+					console.error(`OpenRouter API Error: ${error?.code} - ${error?.message}`)
+					throw new Error(`OpenRouter API Error ${error?.code}: ${error?.message}`)
+				}
+
+				const delta = chunk.choices[0]?.delta
+
+				if ("reasoning" in delta && delta.reasoning && typeof delta.reasoning === "string") {
+					yield { type: "reasoning", text: delta.reasoning }
+				}
+
+				if (delta?.content) {
+					yield { type: "text", text: delta.content }
+				}
+
+				if (chunk.usage) {
+					lastUsage = chunk.usage
+				}
 			}
+		} finally {
+			// Clean up the timeout checker
+			clearInterval(timeoutChecker)
 		}
 
 		if (lastUsage) {

src/core/task/Task.ts

@@ -1810,7 +1810,31 @@ export class Task extends EventEmitter<ClineEvents> {
 		try {
 			// Awaiting first chunk to see if it will throw an error.
 			this.isWaitingForFirstChunk = true
-			const firstChunk = await iterator.next()
+
+			// Add timeout for OpenRouter to prevent indefinite hanging
+			const OPENROUTER_FIRST_CHUNK_TIMEOUT = 30000 // 30 seconds
+			const isOpenRouter = this.apiConfiguration.apiProvider === "openrouter"
+
+			let firstChunk: Awaited<ReturnType<typeof iterator.next>>
+			if (isOpenRouter) {
+				// Create a timeout promise that rejects after the specified time
+				const timeoutPromise = new Promise<never>((_, reject) => {
+					setTimeout(() => {
+						reject(
+							new Error(
+								`OpenRouter API request timed out after ${OPENROUTER_FIRST_CHUNK_TIMEOUT / 1000} seconds. This may be due to high load on OpenRouter's servers. Please try again later or switch to a different provider.`,
+							),
+						)
+					}, OPENROUTER_FIRST_CHUNK_TIMEOUT)
+				})
+
+				// Race between the actual API call and the timeout
+				firstChunk = await Promise.race([iterator.next(), timeoutPromise])
+			} else {
+				// For non-OpenRouter providers, use the original logic
+				firstChunk = await iterator.next()
+			}
+
 			yield firstChunk.value
 			this.isWaitingForFirstChunk = false
 		} catch (error) {