Yeah, I apologize, we got a little off track on your post. I was thinking about that last night and came on here to try to recover. You've mentioned most of what I was thinking of and added another possibility.
I don't know how much age matters but it being really old might make a difference. I was thinking possible contamination too but you mention you did not buy it. Are you sure it was even Sevin and not something else they put in that container?
An unhealthy bird can't handle stress very well, I'd think his health played a big part. How did you apply it? Did you really lay it on thick in an enclosed area? Something about that may have stressed him.
One of the problems with Sevin or any poison is that we tend to overuse them. it shouldn't take much to do the job. In the garden when we overuse Sevin it can kill a lot of the stuff living in your soil. A good garden soil should be full of living organisms from microbe size on up. Over-applying any poison can have unintended consequences, like killing those organisms.
I don't know what was wrong with that rooster or how weak he really was. Parasites like lice and mites tend to really attack weaker animals. I don't doubt that the treatment contributed to his death, not sure exactly how. Sevin if applied properly, mainly out of doors so it and you are not breathing the dust that much, should not harm an otherwise reasonably healthy chicken. I agree, you should wear a dust mask when applying it, even if you are out of doors.
The studies that led to Sevin becoming off-label for chickens are not new. The ones referenced in the justification for the change were from the late 20th century, centered around the 1970's. What's changed is the standard for judging them. It used to be that if something was not known to cause harm it was OK to use. The current standard is that if there is any detectable residue after a certain time period it becomes off-label, whether that caused harm or not. Sevin can still be used legally to treat chickens for mites and lice. You need a prescription form a veterinarian.