I have just fixed this problem.
it was nothing to do with Pearl, we are quite sure it is because of some legacy attributes that did not work with elastic search.
The site was a Magento 1 site and back then I used attributes to assist with the menus pre Mega Menu
Our checking process was to disable Ajax (didnt work), reinstall Ajax(didnt work) change to default theme (didnt work), change attributes to non searchable not all of them just the ones that did not need to be searchable (worked)
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