Blizzard API returns a 404 error for some characters

I don’t know if that might be related, but there are only 3 scenarios as far as I remember that would cause a character not being visible through the API:

For the last scenario we still don’t know exactly what actions would trigger this. I think it would be a good idea for you to also open up a ticket just in case. It can take a while to get an official reply here.

I hope this info can help you solve this somehow. Good luck.