Fortuna Aprilia's Jorge Lorenzo, who can afford to sacrifice 20 points and still claim his second consecutive 250cc title on Sunday, slipped from provisional pole to third on the grid, with championship rival Andrea Dovizioso fourth for Honda.
Alvaro Bautista will start fifth, alongside fellow 125cc world champion Thomas Luthi, with Hector Barbera and Julian Simon completing an all-Aprilia second row.
Alex de Angelis will start ninth after an early accident left him temporarily trapped under a rival's machine.
Final qualifying – Sepang:1. H. Aoyama (KTM)
2. Kallio (KTM) +0.032secs
3. Lorenzo (Aprilia) +0.192secs
4. Dovizioso (Honda) +0.246secs
5. Bautista (Aprilia) +0.356secs
6. Luthi (Aprilia) +0.510secs
7. Barbera (Aprilia) +0.719secs
8. Simon (Honda) +1.067secs
9. de Angelis (Aprilia) +1.316secs
10. Locatelli (Gilera) +1.524secs
20. Laverty (Honda) +3.497secs