If you don't want to activate your card, then just buy the tickets to Tohoku separately.As for getting to the Tohoku area, it depends on how you want to travel. Do you want to stop at places on the way up or go up and then see the sites on your way down? Also, what city in Tohoku is your actual destination?
If you are going to Aomori, you can actually catch a train directly from Kyoto Station. It's a Sleeper Car (night train) and costs \21420, according to Hyperdia. That is the cheapest option from Kansai, and you'll also save money on a hotel, since you'll be sleeping on the train.
If you are going to Sendai, then you could take a Highway Bus (overnight only) to Sendai from Osaka for 12,230yen:
http://www.bus.or.jp/bus/index_e.html
Those are cheap options. Naturally, you could also just take the Shinkansen to Tokyo, transfer trains, and go to Tohoku that way.