That's part of it, but the larger issue has to do with maintenance of their actual rights in the IP. Because of the way copyrights work, Nintendo could lose the right to ever sue anyone for the use of Koffing's likeness if it were to allow sufficiently rampant unauthorized merchandising. It is standard practice for corporations to stamp out even minor infringements in order to prevent things from getting out of hand and risking this.
This is untrue. Genericisation applies to trademarks, not copyright. Copyright can be selectively litigated with no adverse consequences to the copyright holder (other than incidental consequences, like people not being afraid of the copyright holder). This is one of the downsides of using the term "intellectual property" as if the various laws were all the same.
In any case, for any small-time Internet user, the main concern isn't whether something is illegal, it's whether you're prepared to defend yourself when somebody claims it's illegal. The risk of distributing shirts through the Internet should be fairly low though. At worst, the loss would probably be the time already invested into selling the shirts. However, I would say your best bet if you want a shirt related to Smogon would be to use one of the many online services that allow you to order a shirt with an arbitrary picture on it. Perhaps we could provide some designs that you could use in conjunction with such a service.

















