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Broken strand and minimum bend radius
One thing to keep in mind when you see one broken strand is not that you have all of the rest of the strands still there for strength, but that all of those strands have been subjected to the same stress as that broken strand indicating that their useful life is almost depleted. It would be interesting to find the manufacturer of the cable and ask what the minimum allowable bend radius is and see if the radius of the bell crank is under that. Depending on the cable manufacturer and the number/diameter of the strands, maybe there is one choice of cable that is better than the rest.
As far as handling of the cable, you should be able to bend a cable within its specified bend radius and it not break. If you take it and kink it, expect to see broken strands after repeated exercising.
Did anyone measure the diameter of a "bad" cable versus a new replacement cable?
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