Repaint Limits

[Autocon]

Are you saying that each mold is only repainted twice per side, only two autobot and two decepticon? yes Is the "repaint" only counted if it's a different character? yes unless circumstances say otherwise
There's at least five repaints of voyager Optimus, and six for deluxe Jazz.

six? yes but thats op and yes different character depending on circumstances eg bonecrusher

jazz/smokescreen
fbjazz/prem/G1 < special things