I assume AOR USA will not touch it because it is an 'unblocked' version, so not U.S. legal.
In the U.K. the AOR Importer / Dealer have been used as a go-between for people needing their DV1 to be sent to Japan for repair at the Owner's expense. Since unblocked DV1's are legal in the U.K. there was not a problem.
In your case I imagine no U.S. Dealer will help either for the same reason.
You could contact AOR Japan (NOT mention it is unblocked - they will be able to tell from the Serial Number though) and ask them if you can send it to them direct. HOWEVER they may well say you can only do that via a Dealer, so back to square one, or just refuse because your DV1 is 'illegal' in the U.S.
There is one other problem, even if you manage to get it repaired in Japan, you then run the risk of it being seized. by U.S. Customs on the way back. It did get though when you bought it from Germany but less likely when coming back from Japan, assuming AOR Japan would do that. I feel the worst scenario would apply, you having to pay for the repair and transportation, and the Radio ending up 'seized' on its way back into the U.S.
I think the AR-DV1 is not required to be 'blocked' in Canada? If that is the case you might be able to find an AOR Dealer in that Country who would send it to Japan, and there would be no Customs issue when it was returned to them. I have no idea how intense or otherwise are the Customs regarding post between Canada and the U.S.
Personally I would avoid contacting AOR Japan yourself. You risk them 'flagging' the Radio's serial number in the future.
DEALERS | AOR U.S.A., INC. Authority On Radio Communications gives a list of Dealers, with several in Canada. One of them could certainly send the DV1 to Japan and have it returned to them without breaking any U.S. laws, but may still refuse to send it to you in the U.S.
The last alternative would be if you have a friend in Canada who would say the DV1 belonged to them? They should be able to get a Canadian Dealer to get the DV1 repaired and returned to them, then to your friend at their Canadian address. Just the issues of getting it to your friend and then back to you, which may be less of a Customs issue perhaps. If you have such a friend my STRONG advice is for them NOT to try to get the DV1 repaired under guarantee, and from the start say they are willing to pay all the costs.
In any case, good luck. Let me know your decision and how it turns out.