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No clue if this will work but maybe worth a try:
1) Release him
2) Go to player editor and manually place him on your team
3) I believe that would put him somewhere in your system but not sure where since I don't know your setup. At any rate, then try to put him on the active roster
Note: For #1, rather than releasing him you might try instead making him a free agent by going to the player editor and making him a free agent there.
Also, very important: You mention above that you don't want to try your "put him on waivers" idea because you don't want to risk it. So for that, this one, or any other scenario you might try, back up your league first so a) there's no risk, and b) you can try pretty much anything to solve the problem.
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