I think KMC say you should replace it when you replace the chain. Given that they cannot know how many times you undo the link in the life of a chain, I suspect that the link can last for quite a while. I have certainly reused a link half a dozen times. I also carry a new spare one but have never needed to use one out on the road.
I always use the new one supplied when I change a chain. I keep the old ones and always carry one as a spare if I should ever need one when out on a ride. If I was to have to use it it would only be in an emergency situation and the chain would be replaced once I got home.
I think KMC say you should replace it when you replace the chain. Given that they cannot know how many times you undo the link in the life of a chain...
It's not undoing the link that wears it, but normal wear and tear on the pin from friction against the inner link, the same as for any other pin, like that shown in the second pair of images on this page: http://sheldonbrown.com/chains.html
Never had a problem with one, but always use the new and as above keep the old as backup spares, though never needed, I also carry a chain tool so if worst comes to the worst, I can drop a link out.
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