just found this on ctc which might be useful to anyone attempting the gear mod
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Most hub-gears, including Shimano plus Sram-Sachs and most Sturmey-Archer, accept the same, standard, 3-spline pattern of sprocket. They are available with up to 22 teeth (1/8 chain) and Sram also makes a 24T×3/32, so it's easy to lower the gears on a hub-geared bike. The sprocket plus maybe a washer or two are held on by a spring-steel split-ring. Prise that ring out of its groove (with screwdrivers or whatever) and the sprocket simply slides off. Slide on another and snap the ring back.
But first you generally have to remove some part of the gear-change apparatus. In the case of Shimano they call this gubbins a “cassette joint”. It comes off easily too, when you know how. When you don't though …!
The necessary Service Instructions ought to be supplied with the bike. Failing that they can be downloaded from the web. Visit
Shimano Europe Home and browse to Technical Service/Documents for the appropriate hub and shifter.
For those listening in black and white: first shift into gear No.1 and detach the cable by pulling the casing forward out of the "cassette joint bracket"; then sideways so the cable passes through the slit; then back toward the hub so the cable and it's anchor bolt can be lifted from the "cassette joint pulley". Learn this operation well – and its reverse – since it's what you'll often do to remove and replace the wheel.
Now to remove the cassette joint, rotate its fixing ring" 45° (1/8 turn) anticlockwise, then the bracket and pulley assembly simply lifts off the hub "driver". Also lift off the "driver cap", a dished washer, noting the direction of dish, and finally you are ready to get to work on that springy split-ring thing!
To replace the cassette joint on the hub, first don't forget the driver cap, then line up red dots on the pulley, the bracket and the hub. Follow that with the fixing ring, aligning yellow dots this time, on pulley and ring, before twisting the ring 45° clockwise to lock everything in place.
This process of cable and cassette joint removal is virtually the same for all Shimano hubgears with 4 or more speeds, but the joints themselves are not the same so don't mix them around – in some the pulley can be separated from bracket. A bit of cleaning may be needed to reveal the coloured dots!